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Efficient mailing

Sep 1, 2009 12:00 AM

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Postpress, once the bastion of heavy-duty manual labor, is hitting new heights in productivity as automation technology and data integration reach every area of print production — and mailing is no exception. Here's the latest from PRINT 09.

High-speed inserter

Buhrs Americas (Minneapolis) is showcasing its high-speed BB700 Inserter at PRINT 09. With a rated speed of 16,000 pieces per hour, it is the fastest multiformat inserter on the market. Key to the popularity of the Buhrs BB700 Envelope Inserter is its format flexibility. Some machines are rated at high speeds, but can only accommodate a particular envelope format or size. The Buhrs BB700, on the other hand, operates at rated speed over the widest range of envelope sizes in the industry.

Buhrs Americas also is showing a flexible entry-level system for poly wrapping at PRINT 09. With a mechanical speed of 10,000 products per hour, the Buhrs 1000 Solo offers high automation with a touchscreen operating panel and job storage. The gathering section can be configured to suit specific production requirements, and the servo-driven seal mechanism incorporated in the wrapping module ensures reliable and high quality wrapping. Longitudinal sealing, static control, and dual unwinder with automatic tension control and end-of-roll detection are standard features.


Inline fold and tab system

Duplo's (Santa Ana, CA) DT-900 Tabber, connected to a Duplo DF-915 or DF-920 Folder, provides a powerful 14,400 piece per hour inline fold and tab system capable of processing direct mail, newsletters, double postcards and other self-mailers at the touch of a button. It folds and tabs open-ended mailers in a single pass. With a two-tab capability, mail pieces are securely fastened. Built for digital printing, it enables quick turnarounds for 1:1 direct marketing.


Enhanced combo inserter

Böwe Bell + Howell (BBH) (Wheeling, IL) has announced the immediate availability of the Combo 14 inserting system, the latest evolution of its Combo platform. Combining the functionality of multiple inserters, the Combo 14 processes envelopes at rated speeds up to 14,000 cph for No. 10 or 6×9-in. letters and up to 9,000 cph for flats. It offers rapid changeover from flats to letters and the EASE (Every Application Setup Easily) system, designed to dramatically reduce the number of steps required to change over from one size envelope to another. EASE incorporates innovations such as self-locking synchronized guide adjustments and uniform hinge-line registration.

In addition, new input channel modules, new enclosure feeders and enhancements to BBH's VEKtor and JETVision technologies are available. The new 4911 combined accumulator/folder has the option of adding BBH's BIPS (Bowe Interaction Productivity System) to enable automated changeover of the accumulation section of the module. The new enclosure feeder design reduces the time to change inserts. JETVision and VEKtor now have 12-inch wide viewing options, enabling easy setup for integrity or quality checks virtually anywhere on a document.


Efficient mail piece production

InfoPrint's (Boulder, CO) PRINT 09 Automated Document Factory (ADF) highlights include the InfoPrint Postal Optimization Solution. It assists mailers with less returned mail, lower postal rates and, in certain cases, the reduction or elimination of sorter equipment. The new InfoPrint Mailroom Integrity ADF solution automates the mailroom printing and inserting process, allowing the tracking of mailpieces from receipt throughout insertion.


Full text database matching

Lake Image Systems' (Henrietta, NY) camera matching verification software now provides full text database comparison, eliminating the need for marks or identifiers and enabling documents with different values to be matched to a database. The new software, part of the Lake Image Systems IntegraVision IQ suite, enables users to run complex matching applications at maximum inserter or card attacher speeds.

“As the direct mail and similar markets move away from mass marketed pieces to highly personalized content, Lake Image Systems clients must process these unique documents without impacting production performance,” notes vice president Pat Hoskins. “IntegraVision IQ provides this ability, together with the IMB verification, missing and duplicate piece detection, productivity reporting, and other features.”


Flexible configurations

Heidelberg (Kennesaw, GA) Stahlfolder Flexomailers are configured from a wide variety of components, some of which are commonly used in folder configurations such as feeders, register table, slitter shafts, cross carriers, folding stations, gluing accessories, deliveries and a complement of other equipment.

Complete and finished mailings can include envelopes with remoistable glue line, return cards, tipped-in objects such as credit cards, and inkjet personalization. Most direct mail pieces can be produced in multiple-up production for added efficiency. To this end the products are trimmed, slit and cut apart to final size.

In a typical mailer configuration the slitting, scoring and perforating station SSP is the most economical solution, as it can perform more mail piece tasks than a regular folding station. The SSP is a dedicated station and in its function replaces platen presses or other slow devices to perform quality finishing tasks, such as scoring and perforating at a higher efficiency and economy. A folder parallel station also can be used instead of an SSP unit. Stahlfolder TH stations can perform similar applications to the SSP.


Mail masters

Standard Finishing Systems' (Andover, MA) Standard KAS Mailmaster 565HS handles No. 10 to 6.5×9.5-inch envelopes, inserting at speeds up to 7,200 envelopes per hour. It features sequential startup and clear down; simple top load and bottom feed; miss, double and jam detectors; and hand feed or on-line position.

Standard KAS Mailmaster 465HS and 465 Compact Mail Inserters offer quick job changeover, superior document feeding capability, touchscreen controls, and high productivity. Other features include configuration flexibility for custom applications and optional state-of-the-art optical scanning capability for document security and integrity. The Standard KAS Mailmaster 465HS handles No. 10 to 10×13-in. envelopes with a maximum thickness of 0.05 in., inserting at speeds up to 6,000 envelopes per hour. The Standard KAS Mailmaster 465 Compact is a smaller footprint production envelope inserter that can insert at speeds up to 5,000 envelopes per hour, from No. 10 size to 9×12 in. The line of Standard KAS inserters are available in a number of configurations to fit virtually any commercial production environment.


High performance for smaller shops

Xanté (Mobile, AL) is showcasing the latest Xanté Ilumina Digital Envelope Press+ at PRINT 09. With output on envelopes up to 13×15 in., it gives small to midsize shops the ability to print up to 60 full-color envelopes per min. Its 800-piece input capacity supports volume production demands such as those needed for transpromo applications. All Ilumina devices can print on window envelopes. Ilumina also can produce full-color page mailings from its 530-sheet cassette, which has the ability to handle up to 12×18-inch paper. The single-pass, large-format, laser-based system is Adobe PostScript driven and can produce full-color output at up to 36 ppm; monochrome up to 40 ppm.


Smart addressing, mail management

Pitney Bowes' (Stamford, CT) AddressRight DA95F printer with fixed-head technology offers monochrome and color printing. A precision controlled media path helps ensure mail pieces travel through the system accurately and reliably, reducing jams and optimizing productivity. Precise print head position indicators help ensure text and graphics appear exactly where a user wants them. The DA95F can print up to 30,000 No. 10 envelopes per hour and can run mail pieces up to 0.05 in. thick. The printer can be used in tandem with Pitney Bowes's SmartMailer 7 mail management solution, VeriMove Net Move Update solution and suite of mail tracking solutions. The integrated solutions can cleanse and update a mailer's existing list to help meet Move Update requirements, presort the list for postage discounts and track the mailing through the mailstream, leveraging the power of the Intelligent Mail barcode.

The DM575 Digital Mailing System enables customers to move all types of mail efficiently, while helping to save time and money. The system leverages its intelligent software and operational enhancements to provide a consistently reliable, smooth mail processing operation. The DM575 automatically feeds, seals, posts and stacks at speeds up to 175 pieces per minute, and comes equipped with advanced features such as Weigh-On-The-Way with Shape Based Rating. The advanced IntelliLink Command Center enables customers to easily activate and control all the functions of the DM575 from a single, central location. This easy to use technology enables customers to manage, track and charge back postage expenditures, select appropriate carrier choices and gives access to USPS and other carrier's rates and services. As rates change, they can be downloaded directly to the DM575 Digital Mailing System.


Online inkjet label coordination

Muller Martini's (Hauppauge, NY) AddressLinc On-Line Inkjet Labeling option, a part of the WinLincs Packaging Line Control System family, coordinates zone-based newspaper package labeling (printing) by sending various commands and specific information to an inkjet labeler (printer). The information contained within the file, including name, address, carrier sort and address record number, is conveyed onto the final package depending upon the customers desired printing orientation. AddressLinc also produces graphic images that are fixed throughout a specific zone depending on the high-speed inkjet printing system. AddressLinc easily integrates with downstream equipment, specifically the stacker, to create bundle separations in accordance with Postal delivery groups. It communicates with a variety of vendors who provide intelligent, externally controllable high-speed inkjet printers. Additionally, newspaper packages that are rejected due to missed or doubled inserts are detected and the designated label is then printed on the following package in the line; so the sequence of addresses is preserved. AddressLinc is available on Muller Martini's complete inserting product portfolio.


Automated direct mail finishing

Rollem Intl.'s (Anaheim, CA) new Mailstream is a fully automated direct mail finishing system that converts press sheets into finished mail products. Its small footprint is ideal for printers who want to bring mailing services in-house. Process multiple-up mail pieces and perform many functions in one pass: edge-trimming, center slitting, scoring, and pattern perfing; plus remoistenable glue, folding, fugitive glue closure and card tip-on while delivering product to mail trays in ZIP code order.


Scalable inline VDP

The new Videojet (Wood Dale, IL) VIP ControlPro inkjet and bindery line control system from Videojet Technologies Inc. enables control of bindery line components with a single solution. VIP ControlPro can manage a diverse range of equipment, such as saddlestitchers, folders and mail lines, including inside/outside personalization, geographic and demographic binding, and carrier route stacker control. The system also facilitates inline variable-data printing of text, addresses, barcodes and graphics.

“The scalable VIP ControlPro system uses a precise method of product tracking throughout a bindery line for accurate print placement of variable data, significantly minimizing printing errors or irregularities,” says Jason Lund, Videojet graphics product manager. “The system's quick-disconnect design simplifies installation and allows for easier switching among different production lines within a facility, so printers and mailers spend less time on line and job setup.”

The Windows XP PC-based VIP ControlPro system can be upgraded to meet growing production needs. The VIP ControlPro can support all Videojet commercial inkjet graphics printers, including the Videojet BX6000 Series binary array graphics printers, the Videojet 4320 inkjet addressing and imaging system, the Videojet PrintPro digital imaging system and the Videojet Excel 270g inkjet printer, as well as models from other vendors. Data format flexibility supports the standard industry formats for variable data as well as custom formats.


Check out our full PRINT 09 show coverage at