Foolproof Mail Tray Loading

In most shops, separating outbound mail into trays and pallets is a manual process. Machine operators are given sheets of tray tags and other information to which they must refer in order to split the job among the necessary containers as prescribed by the presort software.

When our customers talked with us about their frustration with manually managing mail tray loading and the unreliability of sorting equipment they’ve tried, we went to work designing and building a better solution. The result is iDataSort™, a data-driven module that takes makes it easy for operators to see the tray breaks, load the mail trays, and keep up with a fast-moving production line.

With iDataSort™, distribution mistakes caused by operator error can be eliminated. Postcards coming off an inkjet production line, for instance, can be separated using various methods. The machine jogs side-to-side and adjusts belt speeds as it stacks to indicate the exact location of the tray breaks.

“All the other machines on the market break the groups by changing the belt speed. Sometimes the material slips, making it hard to see the gaps. iDataSort™ offsets side-to-side. This is much better

Roger Higdon

GLS / Next Precision Marketing



iDataSort™ separates groups of printed material so operators can easily load the mail trays. The unit receives sort signals from attached equipment or separates according to a fixed count. A moving belt shifts left or right to create the desired break points. The stacker can also dynamically adjust the speed of the belt, creating a second method to separate batches of materials. Both methods can be invoked in a single job.

After installing iDataSort™, DDS customers report they can fill mail trays twice as fast as before. Keeping up with equipment running at over 40,000 pieces per hour is not a problem for this unit.

Click here to see the iDataSort™ in action!

Besides filling mail trays, print production operations are using iDataSort™ to prepare material for packaging and for handling other unique finishing and distribution requirements. You can attach the unit to any print production or mailing machinery in your shop or run it as a standalone operation. iDataSort™ can even control unintelligent feeders, allowing you to add automation to your workflow without investing in totally new production equipment.

To maintain efficiency, many print service providers are combining small jobs into larger print runs. With varied finishing requirements, multiple mail drops, segmentation, and shipping destinations, the jobs must be accurately separated as they exit the print line. Manual distribution errors are embarrassing and costly. Automated stacking has raised production quality and improved efficiency, allowing your company to service customers-even those with tight deadlines.