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 enclosing device includes an envelope conveyance path, an envelope loader, an envelope-position restrictor, and an envelope-position adjuster. The envelope conveyance path conveys an envelope to an enclosing position at which an enclosure is enclosed into the envelope. The envelope loader loads the envelope to be supplied to the envelope conveyance path. The envelope-position restrictor restricts a loaded position of the envelope in the envelope loader. The envelope-position adjuster adjusts a position of the envelope with respect to a conveyance direction of the envelope while maintaining a state in which the envelope-position restrictor restricts the loaded position of the envelope.

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.

An envelope processing apparatus for enclosing an enclosure in an envelope includes an envelope conveyance path, an enclosure supplier, an envelope supplier, a flap opener, and an envelope stacker. The envelope conveyance path extends in a substantially vertical direction to convey the envelope. The enclosure supplier supplies the enclosure to the envelope via the envelope conveyance path. The envelope supplier supplies the envelope to the envelope conveyance path, The flap opener opens a flap portion of the envelope between the envelope supplier and the envelope conveyance path. The envelope stacker stacks the envelope ejected from the envelope conveyance path.

A letter number specifying unit specifies a letter number of a sealed letter to be informed to a user, based on a content of a transfer error detected by an error detector. A searching unit searches a letter-number-specific print content table, in which letter number identification information for identifying each letter number, and print content information indicating a content of an image to be printed on a sheet which forms the sealed letter of each letter number are associated with each other, and finds the print content information associated with the letter number identification information of a letter number identification code read by a code reader from the sheet which forms the sealed letter of the letter number specified by the letter number specifying unit. An information displaying unit displays the print content information found by the searching unit on a display.

Systems and methods of forming a mailpiece by folding an envelope sheet around one or more insert sheets (e.g., an insert stack) include creating the insert stack, staging the insert stack proximate to the transport path of the envelope sheet, dispensing the insert stack onto the envelope sheet, applying adhesive to the envelope sheet, using a buckle folder to wrap the envelope sheet at least partially around the insert stack to form an unsealed envelope without stopping the envelope sheet and without bending the insert stack, folding the envelope flap of the unsealed envelope onto the back thereof using a plow folder, and sealing the flap of the envelope to the back of the envelope, creating the mailpiece.

An envelope sealing and flipping system can be incorporated into a mail inserter system to seal an envelope with a complete unbroken glue line and simultaneously flip the envelope face-up for downstream processing. The system includes a flip cage that receives an envelope and a moveable wetting brush that contacts the flap. The flip cage rotates, causing the flap to drag underneath the wetting brush, and realigning the envelope with a sealer nip which seals the envelope. The flip cage rotates continuously to receive, flip, and seal many envelopes.

A conveyor system is provided including a conveyor and a plurality of functional trays that are removably attachable to the conveyor. Each tray includes a plate having first and second dimensions that are orthogonal to each other, and the plate includes a coupler configured to be removably attached to the conveyor with the second dimension of the plate being in parallel with a moving direction of the conveyor. The plurality of functional trays include one or more of an envelope-opening mechanism, an item-pushing mechanism, an envelope-closing mechanism, an item-wrapping mechanism, and a tray-height-adjustment mechanism. For example, the item-pushing mechanism includes a pusher slidably coupled to the plate, and a linear actuator configured to move the pusher relative to the plate along the first dimension so as to push an item off the functional tray.

A conveyor system is provided including a conveyor and a plurality of functional trays that are removably attachable to the conveyor. Each tray includes a plate having first and second dimensions that are orthogonal to each other, and the plate includes a coupler configured to be removably attached to the conveyor with the second dimension of the plate being in parallel with a moving direction of the conveyor. The plurality of functional trays include one or more of an envelope-opening mechanism, an item-pushing mechanism, an envelope-closing mechanism, an item-wrapping mechanism, and a tray-height-adjustment mechanism. For example, the item-pushing mechanism includes a pusher slidably coupled to the plate, and a linear actuator configured to move the pusher relative to the plate along the first dimension so as to push an item off the functional tray.

An optimized system and method for application of liquid for moistening adhesive on envelope flaps as part of an automated mail production process. Envelopes with open envelope flaps are transported beneath a moistening brush so that an interior side of the flaps, having adhesive thereon, come into contact with a lower end of the moistening brush. A flow of liquid is provided from a liquid supply coupled to the moistening brush to keep the moistening brush wet as moisture is transferred to the envelope flaps. The rate at which liquid is regulated such that moisture is maintained on the brush and a selected quantity of liquid (a dose) is provided for each envelope flap that it moistened. The dose is automatically determined as a function of physical dimensions of the envelope flap, and to optimize sealing of the envelope without excess dripping.