Abstract: The present invention provides systems and methods for preserving postage discounts in a mailstream location, reprinting removed mailsheets, and returning mailpieces to their originally intended location. Because the sequence of the mailstream is restored, postage discounts based on print stream location are preserved and the correct mailsheets are grouped together to qualify for the postage discount. Advantageously, restoring the sequence of the mailstream in place is more efficient than through a secondary workflow.

Abstract: The invention is a hybrid inserter/wrapper system comprising a hybrid inserter/wrapper system comprising a modular document inserter system and a unique wrapper-like envelope creation module operably connected thereto. The wrapper-like envelope creation module is configured to operate in a first mode and a second mode. In the first mode, the wrapper-like envelope creation module is configured to fabricate wrapper-like outer envelopes and feed such outer envelopes to the inserter system. In the second mode, the wrapper-like envelope creation module is configured to allow the inserter to be loaded with premade envelopes and feed such envelopes to the inserter system. In either mode, the document inserter system further carries out downstream operations to thereby produce a finished mailpiece.

Abstract: The systems and methods of the present invention provide optimized mailpiece batching, production, and mailing based on historical and real time, or near-real time, data such as target delivery time, mail fabrication processing costs and capacity, tracked transit times and costs for mailing between induction points and target addresses, and transport times and costs from various printers to various induction points. Additional considerations such as bulk discounts can be used in the analysis to ensure maximum cost reduction while achieving contract delivery times using distributed printing.

Abstract: The invention is a modular card processing and attaching system configured to provide uninterrupted workflow in the feeding and subsequent attaching of cards to carriers for the formation of a mailpiece. The modular card processing and attaching system is further configured to be incorporated into a production mail inserter system, such that attached card and carrier mailpieces may be subsequently sorted and/or inserted into a mailable envelope or packages to be mailed.

Abstract: A method includes feeding an envelope along an envelope transport path in a paper-handling machine to a flap-opening station. The method further includes opening the flap of the envelope at the flap-opening station and printing on the envelope with the flap in an open position. After printing, a collation is inserted into the envelope.

Abstract: A mailing system includes a mailing machine having an envelope feed path, a sealing system configured to apply a liquid to an envelope in the envelope feed path, a capacitive sensor located in the envelope feed path downstream from the sealing system, and a controller connected to the capacitive sensor. The sealing system may include a liquid reservoir and a liquid applicator. The capacitive sensor is configured to measure a quantity of liquid on a portion of the envelope applied by the sealing system and to generate a signal based on the measured quantity. The controller is configured to perform an operation based on the measured quantity signal from the capacitive sensor.

Abstract: In a mail processing machine, a fixed mounting of an envelope turning station relative to an upstream stuffing station, and therefore a simple construction of the drive for the envelope turning station, can be achieved in that the items of goods for despatch to be turned through 180° are drawn by grippers of a gripper chain into the region of horizontally opening tongs of the envelope turning cylinder of the envelope turning station, in such a way that, in each case irrespective of the longitudinal format of the items of goods for despatch, the latter are gripped by the turning cylinder tongs over their entire length, for which purpose the gripper chain, together with the stuffing table supporting it, is designed to be displaceable with respect to the turning station in the conveying direction of the goods for despatch, in a manner dependent on the envelope format.

Abstract: A mailing system includes a mailing machine having an envelope feed path, a sealing system configured to apply a liquid to an envelope in the envelope feed path, a capacitive sensor located in the envelope feed path downstream from the sealing system, and a controller connected to the capacitive sensor. The sealing system may include a liquid reservoir and a liquid applicator. The capacitive sensor is configured to measure a quantity of liquid on a portion of the envelope applied by the sealing system and to generate a signal based on the measured quantity. The controller is configured to perform an operation based on the measured quantity signal from the capacitive sensor.

Abstract: A method includes feeding an envelope along an envelope transport path in a paper-handling machine to a flap-opening station. The method further includes opening the flap of the envelope at the flap-opening station and printing on the envelope with the flap in an open position. After printing, a collation is inserted into the envelope.

Abstract: A drive apparatus for a mail-processing system is specified, which apparatus has an enclosure-collating path, which is intermittently driven at least in one end section, an adjoining inserting station for sets of enclosures and an envelope-filling table, which extends parallel to the enclosure-collating path and in front of the inserting station and over which envelopes pulled from a stack of envelopes are pulled by means of an envelope-gripper chain in front of the inserting station and held open there and, once filled with the sets of enclosures, are conveyed away by the gripper chain.

Abstract: In a mail inserting machine that a user uses to process mailpieces for a prepaid quantity, a counter is installed in an inaccessible manner to keep count of the processed mailpieces. The machine is disabled when the prepaid quantity is used up. In order to allow the user to pay for additional quantity, the manufacturer embeds a finite number of unlocking codes in the machine. Each code for the particular machine is activated in sequence. When the user needs to replenish the inserter counter, he calls the service counter and gives his machine serial number. The user is given the next unlocking code after he agrees to pay for the additional amount. The user can enter the code to unlock the additional preset quantity. The same code will not work again. In a further embodiment, the rate of mailpiece processing is also monitored to ensure that design limitations are not exceeded. The machine is automatically shut down when a predetermined processing rate is exceeded.

Abstract: In the case of an envelope-turning station with a turning cylinder which is oriented parallel to the mail-conveying direction and is equipped with openable and closable jaws on its circumference, it is possible, following charging of the turning-cylinder jaws with horizontally flat items of mail and rotation of the turning cylinder through 90° and/or 270°, for a mail removal arrangement to remove items of mail in the mail-conveying direction, in a state in which they are standing on one of their longitudinal edges, and to feed them to further processing or handling stations of a mail-processing installation.

Abstract: A simplification of the drive for an inserting station for envelope-filling machines is achieved by a carrier on which inserting fingers for inserting material for envelopes into opened envelopes held ready next to a base plate are articulated having the form of a carriage which is horizontally displaceable, transversely in relation to the conveying direction of an enclosure-collating path charging the base plate with enclosures or sets of enclosures, on pushing-guiding paths freely spanning the base plate, the carriage being coupled by means of a link connected to it in an articulated manner to a rocking lever, which is fastened on a rocking shaft which is mounted on the machine frame at a specific distance above the base plate and the carriage, is parallel to the conveying direction of the enclosure-collating path and forms in particular part of a rocking drive shaft, on which the gripping arms of the enclosure and discharge stations lined up along the enclosure-collating path are fastened.

Abstract: In an envelope-filling machine, a clear and simplified construction of the drive system is achieved for the enclosure-collating path, for the enclosure-feeding stations and for the parts of the envelope-filling station, in that a drive motor and a step-down gear mechanism, a bevel gear mechanism and a step-by-step motion linkage are arranged in a row along a main shaft which extends in the longitudinal direction of the machine and is arranged so as to be offset out of the region below the enclosure cassettes of the enclosure-feeding station, and the main shaft is guided through the step-down gear mechanism and the bevel gear mechanism as far as a coupling point for a crank mechanism in order to actuate a pivoting shaft which is common to the gripper arms of the enclosure-feeding stations.

Abstract: A drive apparatus for a mail-processing system is specified, which apparatus has an enclosure-collating path, which is intermittently driven at least in one end section, an adjoining inserting station for sets of enclosures and an envelope-filling table, which extends parallel to the enclosure-collating path and in front of the inserting station and over which envelopes pulled from a stack of envelopes are pulled by means of an envelope-gripper chain in front of the inserting station and held open there and, once filled with the sets of enclosures, are conveyed away by the gripper chain.

Abstract: A simplification of the drive for an inserting station for envelope-filling machines is achieved by a carrier on which inserting fingers for inserting material for envelopes into opened envelopes held ready next to a base plate are articulated having the form of a carriage which is horizontally displaceable, transversely in relation to the conveying direction of an enclosure-collating path charging the base plate with enclosures or sets of enclosures, on pushing-guiding paths freely spanning the base plate, the carriage being coupled by means of a link connected to it in an articulated manner to a rocking lever, which is fastened on a rocking shaft which is mounted on the machine frame at a specific distance above the base plate and the carriage, is parallel to the conveying direction of the enclosure-collating path and forms in particular part of a rocking drive shaft, on which the gripping arms of the enclosure and discharge stations lined up along the enclosure-collating path are fastened.

Abstract: In a mail inserting machine that a user uses to process mailpieces for a prepaid quantity, a counter is installed in an inaccessible manner to keep count of the processed mailpieces. The machine is disabled when the prepaid quantity is used up. In order to allow the user to pay for additional quantity, the manufacturer embeds a finite number of unlocking codes in the machine. Each code for the particular machine is activated in sequence. When the user needs to replenish the inserter counter, he calls the service counter and gives his machine serial number. The user is given the next unlocking code after he agrees to pay for the additional amount. The user can enter the code to unlock the additional preset quantity. The same code will not work again. In a further embodiment, the rate of mailpiece processing is also monitored to ensure that design limitations are not exceeded. The machine is automatically shut down when a predetermined processing rate is exceeded.

Abstract: In a mail processing machine, a fixed mounting of an envelope turning station relative to an upstream stuffing station, and therefore a simple construction of the drive for the envelope turning station, can be achieved in that the items of goods for despatch to be turned through 180° are drawn by means of grippers of a gripper chain into the region of horizontally opening tongs of the envelope turning cylinder of the envelope turning station, in such a way that, in each case irrespective of the longitudinal format of the items of goods for despatch, the latter are gripped by the turning cylinder tongs over their entire length, for which purpose the gripper chain, together with the stuffing table supporting it, is designed to be displaceable with respect to the turning station in the conveying direction of the goods for despatch, in a manner dependent on the envelope format.

Abstract: In an envelope-filling machine, a clear and simplified construction of the drive system is achieved for the enclosure-collating path, for the enclosure-feeding stations and for the parts of the envelope-filling station, in that a drive motor and a step-down gear mechanism, a bevel gear mechanism and a step-by-step motion linkage are arranged in a row along a main shaft which extends in the longitudinal direction of the machine and is arranged so as to be offset out of the region below the enclosure cassettes of the enclosure-feeding station, and the said main shaft is guided through the step-down gear mechanism and the bevel gear mechanism as far as a coupling point for a crank mechanism in order to actuate a pivoting shaft which is common to the gripper arms of the en the enclosure-feeding stations.

Abstract: In the case of an envelope-turning station with a turning cylinder which is oriented parallel to the mail-conveying direction and is equipped with openable and closable jaws on its circumference, it is possible, following charging of the turning-cylinder jaws with horizontally flat items of mail and rotation of the turning cylinder through 90° and/or 270°, for a mail removal arrangement to remove items of mail in the mail-conveying direction, in a state in which they are standing on one of their longitudinal edges, and to feed them to further processing or handling stations of a mail-processing installation.