INTEGRATED APPLICATION
Inline Electronic Mail Sorting
87,000 Pieces an Hour — Proven: One person on the conveyor. They watch for gaps, not zip codes.
The Feeder Never Stops: The conveyor speeds up to make the gap. The line keeps running at full speed.
Conveyor or Stacker: Send the signal to a conveyor to get gaps in the mail — or to a smart stacker to get sorted bundles.
Executive Summary
On most addressing lines, sorting is still done by eye. Someone watches for sort marks or zip-code changes to know where to bundle and tray the mail. That works — but only as fast as a person can read. Past that speed, the person is the slow part, not the machine.
Electronic sorting gives that job to the machine. Your presort software already puts a mark in the mail file at every bundle and tray break. As the inkjet addresses each piece at full speed, it sees that mark and sends a signal out through its I/O outputs. The conveyor gets the signal and speeds up for a moment. That opens a gap in the stream of mail. Your operator watches for gaps — not zip codes. The same signal can go to a smart stacker instead. On a bindery line, that means sorted bundles of books come off the back.
Three things have to work together: an inkjet with I/O outputs, a conveyor or stacker that can take the signal, and presort software that puts the marks in the file. Many newer inkjets already have this built in — most shops just never hooked it up. Mailtech sets up the whole thing: hardware, wiring, and settings. On a new line or the one you already own.
Key Advantages
Run at Machine Speed: The printer sets the pace — not how fast someone can read.
One Person on the Back End: Watching for gaps takes one person, even at speeds where reading marks would take a crew.
Often No New Machine Needed: If your inkjet has I/O outputs, this is mostly a conveyor and setup job on the line you own.
Two Ways to Make the Break: Speed up the conveyor (best — the feeder never stops), or pause the feeder when the job calls for it.
Works on Bindery Lines: Send the signal to a smart stacker and sorted bundles come right off your stitcher.
How It Works
MARK: Your presort software (like BCC Mail Manager) puts a mark in the mail file at every bundle and tray break.
SIGNAL: When the inkjet addresses a marked piece, it sends a signal to the conveyor or stacker.
BREAK: The conveyor speeds up to open a gap in the mail — or the stacker drops a finished, sorted bundle.
Frequently Asked Questions
Can I add electronic sorting to my inkjet addressing line?
A lot of the time, yes. If your inkjet has I/O outputs, you mostly need the right conveyor and setup — not a new machine. If it doesn't, a new print head adds sorting and more speed at the same time.
Will my equipment accept the signals from a new inkjet?
It depends on your conveyor or stacker. It has to take the signal and change speed on command. Send us your model numbers and we'll tell you.
Why speed up the conveyor instead of stopping the feeder?
Stopping the feeder works, but it slows the whole line down. Speeding up the conveyor keeps everything at full speed and still leaves a clear gap.
Where do the sort marks come from?
Your presort software puts them in the mail file at every bundle and tray break. Most programs, including BCC Mail Manager, do this out of the box.
What does it cost to add electronic sorting?
It depends on what you already own. If your inkjet has I/O outputs, it's mostly a conveyor and setup job. If not, a new print head is the bigger step — but it adds speed too. Send us what's on your line and we'll give you your number.