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.

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.

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.

An enclosing-sealing apparatus includes a flap opener that opens a flap of an envelope while the envelope is conveyed to an enclosing position. A first envelope detector is disposed upstream from the flap opener in an envelope conveyance direction and detects both ends of the envelope in the envelope conveyance direction. A second envelope detector is disposed downstream from the flap opener in the envelope conveyance direction and detects both ends of the envelope in the envelope conveyance direction in an open state in which the flap opens. A controller determines the open state of the flap based on a first detection result sent from the first envelope detector and a second detection result sent from the second envelope detector. The controller performs troubleshooting for enclosing the enclosure into the envelope if the controller determines that the open state of the flap is faulty.

An envelope processing apparatus for enclosing an enclosure into an envelope conveyed to an enclosing position includes a conveyance roller that conveys the envelope to the enclosing position. A first envelope length calculator calculates a first envelope length of the envelope in an envelope conveyance direction in which the envelope is conveyed in a close state in which a flap of the envelope closes. A flap opener opens the flap while the conveyance roller conveys the envelope. A second envelope length calculator calculates a second envelope length of the envelope in the envelope conveyance direction in an open state in which the flap opens. A controller calculates a flap length of the flap in the envelope conveyance direction based on the first envelope length and the second envelope length. The controller controls enclosing of the enclosure into the envelope based on the flap length.

An envelope inserting system has an envelope duct for empty envelopes, a transport device for transporting the envelopes from the duct to a packing pocket, a feeding device for feeding the envelope content to and into the pocket, and an outlet-transport device for reforwarding the filled envelope. The transport device has an envelope tunnel mounted movably on the inserting system about a pivot axis, upper and lower tunnel guidances for aligning the envelope with the pocket, and a swivel device operatively connected to the tunnel, and at least one drivable envelope pusher roll. The roll, in a first position, which the tunnel and roll occupy relative to the pocket, is fed from below against the downstream end portion of the upper tunnel guidance and a lower edge of an end edge of the end region is offset downwards relative to a plane defined by the guiding surface of the pocket.

An envelope processing apparatus that inserts an enclosure into an envelope includes an envelope conveyor, a flap opener, an enclosure pusher, and circuitry. The envelope conveyor extends in a vertical direction and conveys the envelope to an enclosing position via an envelope conveyance passage as a passage in which the envelope is conveyed. The flap opener opens a flap of the envelope. The enclosure pusher pushes the enclosure toward an opening of a body of the envelope conveyed to the enclosing position with the flap open. The circuitry changes a pushing amount of the enclosure into the envelope and adjusts the pushing amount based on the opening of the body of the envelope within a specified range from an inside to an outside of the body of the envelope.

Systems, mechanisms, and methods are described that relate to the production of a custom printed insert(s) that can be custom printed prior to insertion of the custom printed insert(s) into an envelope along with a personalized card/carrier combination for mailing to the intended holder of the personalized card. The inserts are custom printed using an insert printer that is located in the inserter mechanism that is used to insert the insert(s) and the card/carrier combination into an envelope for mailing to an end user of the card. The inserter mechanism can have an off-line configuration, i.e. configured as a stand-alone mechanism, or configured for in-line use, i.e. used together with other mechanisms.

Systems, mechanisms, and methods are described that relate to the production of a custom printed insert(s) that can be custom printed prior to insertion of the custom printed insert(s) into an envelope along with a personalized card/carrier combination for mailing to the intended holder of the personalized card. The inserts are custom printed using an insert printer that is located in the inserter mechanism that is used to insert the insert(s) and the card/carrier combination into an envelope for mailing to an end user of the card. The inserter mechanism can have an off-line configuration, i.e. configured as a stand-alone mechanism, or configured for in-line use, i.e. used together with other mechanisms.

A card/carrier combination sorter system is described that is configured for use with a card/carrier combination production system. The sorter system includes an input that is in communication with an output of the production system so as to receive a plurality of card/carrier combinations one-by-one from the production system. The sorter system is configured to sort the plurality of card/carrier combinations into one or more bins of the sorter system. In some embodiments, a card/carrier combination is not diverted and is instead output through an output of the sorter system to an inserter system for insertion into an envelope and subsequent mailing.