Abstract: An apparatus inserts documents into envelopes and includes a document insert station and a document conveyor that conveys documents to be inserted within envelopes to the document insert station. Each envelope has an envelope opening and a flap to close the opening and defines a hinge line. An envelope feeder feeds envelopes upside down on the hinge line with the flap up into the document insert station and angled from the document conveyor. An insert plate is positioned at the document insert station that receives a document conveyed from the document conveyor and includes orifices though which air is blown onto the envelope fed into the document insert station to open the envelope and receive a document conveyed from the document conveyor.

Abstract: An apparatus inserts documents into envelopes and includes a document insert station and a document conveyor that conveys documents to be inserted within envelopes to the document insert station. Each envelope has an envelope opening and a flap to close the opening and defines a hinge line. An envelope feeder feeds envelopes upside down on the hinge line with the flap up into the document insert station and angled from the document conveyor. An insert plate is positioned at the document insert station that receives a document conveyed from the document conveyor and includes orifices though which air is blown onto the envelope fed into the document insert station to open the envelope and receive a document conveyed from the document conveyor.

Abstract: A folding machine includes an accumulator that accumulates at least one sheet of flexible substrate material. A knife folder is adjacent the accumulator and has a knife fold plate that receives the at least one sheet and a knife blade that reciprocates against the at least one sheet. Buckle fold drive rollers are adjacent the knife folder and receive the at least one sheet driven from the knife blade to form a knife fold. At least one buckle folder is oriented along the buckle fold drive rollers and receives a knife fold to form a buckle fold in the at least one sheet.

Abstract: A flexographic printing station prints at least one print stripe of opaque scratch-off coating onto the surface of the card over a PIN as a card member is advanced into a printing station. A print cylinder has a circumferential printing surface that engages an Anilox metering roll and receives the scratch-off coating therefrom and transfers the scratch-off coating from the printing surface onto the surface of the debit card. A controller controls movement of the print cylinder via a mounting mechanism into and out of engagement with the surface of the debit card at a predetermined location and for a predetermined length of time to apply at least one print stripe of predetermined length onto the surface of the debit card based on the length of time the printing surface engages the surface of the debit card.

Abstract: A flexographic printing station prints at least one print stripe of opaque scratch-off coating onto the surface of the card over a PIN as a card member is advanced into a printing station. A print cylinder has a circumferential printing surface that engages an Anilox metering roll and receives the scratch-off coating therefrom and transfers the scratch-off coating from the printing surface onto the surface of the debit card. A controller controls movement of the print cylinder via a mounting mechanism into and out of engagement with the surface of the debit card at a predetermined location and for a predetermined length of time to apply at least one print stripe of predetermined length onto the surface of the debit card based on the length of time the printing surface engages the surface of the debit card.

Abstract: A flexographic printing station prints at least one print stripe of opaque scratch-off coating onto the surface of the card over a PIN as a card member is advanced into a printing station. A print cylinder has a circumferential printing surface that engages an Anilox metering roll and receives the scratch-off coating therefrom and transfers the scratch-off coating from the printing surface onto the surface of the debit card. A controller controls movement of the print cylinder via a mounting mechanism into and out of engagement with the surface of the debit card at a predetermined location and for a predetermined length of time to apply at least one print stripe of predetermined length onto the surface of the debit card based on the length of time the printing surface engages the surface of the debit card.

Abstract: A flexographic printing station prints at least one print stripe of opaque scratch-off coating onto the surface of the card over a PIN as a card member is advanced into a printing station. A print cylinder has a circumferential printing surface that engages an Anilox metering roll and receives the scratch-off coating therefrom and transfers the scratch-off coating from the printing surface onto the surface of the debit card. A controller controls movement of the print cylinder via a mounting mechanism into and out of engagement with the surface of the debit card at a predetermined location and for a predetermined length of time to apply at least one print stripe of predetermined length onto the surface of the debit card based on the length of time the printing surface engages the surface of the debit card.

Abstract: The system and method of the present invention forms an item specific pattern on a plain or holographic metallized film or hot stamp foil, including an embossed substrate with or without holograms. A piezoelectric ink jet printhead includes a plurality of ink jet channels and respective ink jets that receive an etchant-resistant mask material for ejecting etchant-resistant mask material through the respective ink jets onto a metallized surface of the metallized film or hot stamp foil. A controller individually and digitally controls the ejection of etchant-resistant mask material in a programmed manner for ink jet printing on the metallized surface a unique pattern of etchant or etchant-resistant mask. Etchant etches the metallized surface into an item specific pattern using subsequently applied etchant that exposes the metallized surface devoid of the etchant-resistant mask.

Abstract: The system and method of the present invention forms an item specific pattern on a plain or holographic metallized film or hot stamp foil, including an embossed substrate with or without holograms. An ink jet printhead includes a plurality of ink jet channels and respective ink jets that receive one of etchant or etchant-resistant mask material for ejecting etchant or etchant-resistant mask material through the respective ink jets onto a metallized surface of the metallized film or hot stamp foil. A controller individually and digitally controls the ejection of etchant or etchant-resistant mask material in a programmed manner for ink jet printing on the metallized surface a unique pattern of etchant or etchant-resistant mask. Etchant etches the metallized surface into an item specific pattern by the ink jet printed etchant or subsequently applied etchant that exposes the metallized surface devoid of the etchant-resistant mask.

Abstract: A method of forming a debit card and a debit card formed by the method are disclosed. A planar card member has opposing surfaces. A PIN is printed on one of the surfaces. The planar card member is advanced along a predetermined path of travel such as on a conveyor. A radiation cured, opaque scratch-off coating is applied onto the surface having the PIN such that the PIN is covered by the applied scratch-off coating. The scratch-off coating is radiation cured, preferably by ultraviolet radiation.

Abstract: The system and method of the present invention forms an item specific pattern on a plain or holographic metallized film or hot stamp foil, including an embossed substrate with or without holograms. An ink jet printhead includes a plurality of ink jet channels and respective ink jets that receive one of etchant or etchant-resistant mask material for ejecting etchant or etchant-resistant mask material through the respective ink jets onto a metallized surface of the metallized film or hot stamp foil. A controller individually and digitally controls the ejection of etchant or etchant-resistant mask material in a programmed manner for ink jet printing on the metallized surface a unique pattern of etchant or etchant resistant mask. Etchant etches the metallized surface into an item specific pattern by the ink jet printed etchant or subsequently applied etchant that exposes the metallized surface devoid of the etchant-resistant mask.

Abstract: A method of forming a debit card and a debit card formed by the method are disclosed. A planar card member has opposing surfaces. A PIN is printed on one of the surfaces. The planar card member is advanced along a predetermined path of travel such as on a conveyor. A radiation cured, opaque scratch-off coating is applied onto the surface having the PIN such that the PIN is covered by the applied scratch-off coating. The scratch-off coating is radiation cured, preferably by ultraviolet radiation.

Abstract: A method of forming a debit card and a debit card formed by the method are disclosed. A planar card member has opposing surfaces. A PIN is printed on one of the surfaces. The planar card member is advanced along a predetermined path of travel such as on a conveyor. A radiation cured, opaque scratch-off coating is applied onto the surface having the PIN such that the PIN is covered by the applied scratch-off coating. The scratch-off coating is radiation cured, preferably by ultraviolet radiation.