Abstract: A light sensor-containing apparatus for detecting the thickness of inserts placed within a mailer including a picker arm, movable picker jaw that pivots during an insert gripping process, a target plate having a light reflective surface and secured to the picker arm end that moves when gripping an insert, and a light sensor mounted to the picker arm that emits a light beam and receives a reflected light beam that is reflected back from the light reflective surface to establish the thickness of the insert as controlled by associated computer programming is presented.

Abstract: A system and method of sorting documents utilizing an algorithm or routine that alternates an order of documents with smallest sheet count documents followed by largest sheet count documents in order to optimizes a document throughput of an inserter based on a maximum speed that documents can be collated and accumulated and an algorithm or routine for optimizing the document throughput of a dual sheet cutter by grouping even sheet count documents together on evenly paired sheet boundaries within a mailing group of printed documents, with or without the use of dynamic motion control of the inserter.

Abstract: A paper roll cart for storing, holding for usage, and transporting a variably-sized roll of paper includes a wheeled base, a paper roll support that is rotationally mounted to the wheeled base, a paper roll securing mechanism coupled to the wheeled base for releasably anchoring the paper roll to the cart, and a cart movement control system attached to the wheeled base for assisting in the movement of the paper cart from one location to another location.

Abstract: A system and method of operation for proactively grouping disparate mail items that are queued to be produced in a processing facility, wherein the system and method utilize a manufacturing completion schedule for virtually grouping the mail items before physical production occurs and the system and method maximizes profitability by discounting the mail items by applying appropriate discount mailing regulations for virtually grouping the mail items before physical production occurs.

Abstract: A dynamic cue signal generator and method for processing one or more input and output signals to synchronize the operation of one or more associated machines and includes processes for creating a signal delay between receiving an input signal and issuing an output signal, for conditioning an input signal to produce an output signal with required parameters, for producing a plurality of outputs signals, for filling in undetected cues in an input signal to create a filled-in output signal, for filtering noise from an input signal to generate a noiseless output signal, and for generating an error output signal to indicate that an unusual event occurs in an input signal.

Abstract: A system and method of operation for proactively grouping disparate mail items that are queued to be produced in a processing facility, wherein the system and method utilize a manufacturing completion schedule for virtually grouping the mail items before physical production occurs and the system and method maximizes profitability by discounting the mail items by applying appropriate discount mailing regulations for virtually grouping the mail items before physical production occurs.

Abstract: A reduced-ink barcode is disclosed in which the barcode has printed dot foreground and non-printed background element regions assembled into a detectable pattern on a document and is printed with each of the printed dot foreground element regions having less than a maximum printed dot density.

Abstract: A system and method of sorting documents utilizing an algorithm or routine that alternates an order of documents with smallest sheet count documents followed by largest sheet count documents in order to optimizes a document throughput of an inserter based on a maximum speed that documents can be collated and accumulated and an algorithm or routine for optimizing the document throughput of a dual sheet cutter by grouping even sheet count documents together on evenly paired sheet boundaries within a mailing group of printed documents, with or without the use of dynamic motion control of the inserter.

Abstract: A reduced-ink barcode is disclosed in which the barcode has printed dot foreground and non-printed background element regions assembled into a detectable pattern on a document and is printed with each of the printed dot foreground element regions having less than a maximum printed dot density.

Abstract: A system, apparatus, and method for printer-lane-packaging of documents utilizing a printer for printing on a linear web medium documents having fixed-data and variable-data information to produce in-lane formatting for each of the document and including a web cutter for cutting each of the in-lane printed documents into a stream of shingled sheets, a folder and collator for folding and collating the stream of shingled sheets into folded sets of variable page-counts per set for storage or immediate subsequent processing, and a computer for controlling the overall operation of the system components.