Abstract: A method is provided for using a rotatable insertion horn to open an envelope prior to insertion of documents. A pair of insertion horns is positioned at the sides of an envelope inserting station. An envelope is fed into the envelope inserting station with its flap open. The collation of documents is pushed into the open end of the envelope. The insertion horns are positioned in an initial position that is fully outside the envelope, prior to arrival of the collation. The insertion horns are controlled to simultaneously rotate into the envelope as the collation passes between the insertion horns. Preferably, rotation of the insertion horns into the envelope does not begin until a lead edge of the collation is in a region between the insertion horns. This facilitates insertion of the collation without catching on an upstream edge of the insertion horns.

Abstract: A method for automated insertion of a collation into an envelope. The envelope is fed onto an insert station. A preferred insertion depth is determined for the collation to be inserted into the envelope. The collation is pushed via a pusher that moves at a constant velocity towards an open end of the envelope. The location of the pusher is monitored as it approaches the insert station. The envelope is accelerated in the downstream direction from its stopped position to the constant velocity of the pusher. Acceleration is triggered by the pusher reaching a position whereby the envelope and the pusher will match velocities at the same time that the collation is at the insertion depth. As a result, the collation is inserted in the envelope to the insertion depth at the same time that the velocity of the envelope matches the velocity of the pusher.