System for integrated production of envelopes and contents thereof

Abstract

A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system including at least one printing controller capable of receiving personalized printing data from at least one data source, the personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for the multiplicity of envelopes and is matched to individual envelope addresses, the at least one printing controller being operative to merge and order the personalized printing data from the at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings and at least one production facility for the individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of the at least one production facility including at least one digital printer operative to print the personalized printing data including the envelope address information for a plurality of envelopes to be formed from a substrate and the personalized envelope contents information for contents of the plurality of envelopes, at least one cutting stage receiving a printed output from the at least one digital printer and being operative to cut at least one of envelope sheets according to an envelope shaped blank and envelope contents sheets, at least one content-containing envelope formation stage operative to wrap the envelope sheets over the envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto and a bundling stage, gathering and bundling the sealed individually addressed envelopes containing personalized contents matched thereto in the desired distribution sorting order.

1 . A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising:
 at least one printing controller capable of receiving personalized printing data from at least one data source, said personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for said multiplicity of envelopes and is matched to individual envelope addresses, said at least one printing controller being operative to merge and order said personalized printing data from said at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings; and   at least one production facility for said individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of said at least one production facility comprising:
 at least one digital printer operative to print said personalized printing data including said envelope address information for a plurality of envelopes to be formed from a substrate and said personalized envelope contents information for contents of said plurality of envelopes; 
 at least one cutting stage receiving a printed output from said at least one digital printer and being operative to cut at least one of envelope sheets according to an envelope shaped blank and envelope contents sheets; 
 at least one content-containing envelope formation stage operative to wrap said envelope sheets over said envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto; and 
 a bundling stage, gathering and bundling said sealed individually addressed envelopes containing personalized contents matched thereto in said desired distribution sorting order. 
   
     
     
         2 . A system according to  claim 1  and wherein said at least one printing controller is capable of receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run. 
     
     
         3 . A system according to  claim 1  and wherein said desired distribution sorting order is according to postal code. 
     
     
         4 . A system according to  claim 3  and wherein said desired distribution sorting order is according to the delivery order of a mailman's route. 
     
     
         5 . A system according to  claim 1  and wherein said at least one production facility comprises a plurality of production facilities geographically distributed close to correspondingly geographically distributed bulk mail drop-off locations. 
     
     
         6 . A system according to  claim 1  and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope. 
     
     
         7 . A system according to  claim 1  and wherein said at least one cutting stage is capable of receiving said printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form. 
     
     
         8 . A system according to  claim 1  and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage. 
     
     
         9 . A system according to  claim 1  and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output from said at least one digital printer and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of envelope sheets and envelope contents sheets. 
     
     
         10 . A system according to  claim 1  and wherein said envelopes include personalized printing both on the front and the back thereof. 
     
     
         11 . A system according to  claim 1  and wherein said contents of said envelopes is printed on a different substrate than said substrate. 
     
     
         12 . A system according to  claim 1  and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets. 
     
     
         13 . A system according to  claim 1  and wherein:
 said at least one digital printer is operative to print said envelope address information separately from printing said personalized envelope contents information,   said at least one cutting stage comprises a plurality of cutting stages, at least one of said plurality of cutting stages receiving a first printed output corresponding to said envelope address information and being operative to cut said first printed output into said envelope sheets and at least one other of said plurality of cutting stages receiving a second printed output corresponding to said personalized envelope contents information and being operative to cut said second printed output into said envelope contents sheets,   and wherein said envelope sheets formed of said first printed output and said envelope contents sheets formed of said second printed output are merged in said at least one content-containing envelope formation stage.   
     
     
         14 . A system according to  claim 1  and wherein prior to said at least one content-containing envelope formation stage at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert. 
     
     
         15 . A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising:
 at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of said multiplicity of envelopes, said contents of said multiplicity of envelopes containing a variable number of sheets, which varies from one of said multiplicity of envelopes to another of said multiplicity of envelopes; and   at least one content-containing envelope formation stage operative to wrap envelope sheets over envelope contents sheets containing a variable number of sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto having a variable number of sheets.   
     
     
         16 . A system according to  claim 15  and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said envelope contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope. 
     
     
         17 . A system according to  claim 15  and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets. 
     
     
         18 . A system according to  claim 15  and also comprising at least one cutting stage capable of receiving printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form and being operative to cut said printed output into at least one of said envelope sheets and said envelope contents sheets, said envelope sheets being cut according to an envelope shaped blank. 
     
     
         19 . A system according to  claim 18  and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage. 
     
     
         20 . A system according to  claim 18  and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of said envelope sheets and said envelope contents sheets. 
     
     
         21 . A system according to  claim 15  and wherein said sealed individually addressed envelopes include personalized printing both on the front and the back thereof. 
     
     
         22 . A system according to  claim 15  and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert. 
     
     
         23 . A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising:
 at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of said multiplicity of envelopes; and   at least one content-containing envelope formation stage operative to wrap envelope sheets over envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto, said sealed individually addressed envelopes including personalized printing both on the front and the back thereof.   
     
     
         24 . A system according to  claim 23  and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said envelope contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope. 
     
     
         25 . A system according to  claim 23  and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets. 
     
     
         26 . A system according to  claim 23  and also comprising at least one cutting stage capable of receiving printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form, and being operative to cut said printed output into at least one of said envelope sheets and said envelope contents sheets, said envelope sheets being cut into according to an envelope shaped blank. 
     
     
         27 . A system according to  claim 26  and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage. 
     
     
         28 . A system according to  claim 26  and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of said envelope sheets and said envelope contents sheets. 
     
     
         29 . A system according to  claim 23  and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert. 
     
     
         30 . A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising:
 at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of said multiplicity of envelopes;   at least one cutting stage receiving a printed output from said at least one digital printer and being operative to cut at least one of envelope sheets and envelope contents sheets;   at least one content-containing envelope formation stage operative to wrap said envelope sheets over said envelope contents sheets and thereby coterminously create envelopes and the content thereof in sealed individually addressed envelopes containing personalized content matched thereto.   
     
     
         31 . A system according to  claim 30  and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over envelope contents sheets containing a variable number of sheets, such that said sealed individually addressed envelopes have a variable number of sheets. 
     
     
         32 . A system according to  claim 30  and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said envelope contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope. 
     
     
         33 . A system according to  claim 30  and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets. 
     
     
         34 . A system according to  claim 30  and wherein said at least one cutting stage is capable of receiving said printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form. 
     
     
         35 . A system according to  claim 30  and wherein said sealed individually addressed envelopes include personalized printing both on the front and the back thereof. 
     
     
         36 . A system according to  claim 30  and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage. 
     
     
         37 . A system according to  claim 30  and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of said envelope sheets and said envelope contents sheets. 
     
     
         38 . A system according to  claim 30  and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert. 
     
     
         39 . A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising:
 at least one printing controller capable of receiving personalized printing data from at least one data source, said personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for said multiplicity of envelopes and is matched to individual envelope addresses, said at least one printing controller being operative to order said personalized printing data from said at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings; and   at least one production facility for producing said individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of said at least one production facility comprising:
 at least one printer operative to print said personalized printing data including envelope address information for a plurality of envelopes and personalized envelope contents information for contents of said plurality of envelopes; 
 at least one envelope/envelope contents differentiation stage receiving a printed output from said at least one printer and being operative to provide envelope sheets and envelope contents sheets; 
 at least one content-containing envelope formation stage operative to wrap said envelope sheets over said envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto; and 
 a bundling stage, gathering and bundling said sealed individually addressed envelopes containing personalized contents matched thereto in said desired distribution sorting order. 
   
     
     
         40 . A system according to  claim 39  and wherein said at least one printing controller is capable of receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run. 
     
     
         41 . A system according to  claim 39  and wherein said desired distribution sorting order is according to postal code. 
     
     
         42 . A system according to  claim 41  and wherein said desired distribution sorting order is according to the delivery order of a mailman's route. 
     
     
         43 . A system according to  claim 39  and wherein said at least one production facility comprises a plurality of production facilities geographically distributed close to correspondingly geographically distributed bulk mail drop-off locations. 
     
     
         44 . A system according to  claim 39  and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope. 
     
     
         45 . A system according to  claim 39  and wherein said at least one envelope/envelope contents differentiation stage is capable of receiving said printed output in at least two of roll, sheet and fan-fold form. 
     
     
         46 . A system according to  claim 39  and wherein said at least one envelope/envelope contents differentiation stage operates asynchronously to the operation of said at least one content-containing envelope formation stage. 
     
     
         47 . A system according to  claim 39  and wherein said envelopes include personalized printing both on the front and the back thereof. 
     
     
         48 . A system according to  claim 39  and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets. 
     
     
         49 . A system according to  claim 39  and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert. 
     
     
         50 . A method for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the method comprising:
 receiving personalized printing data from at least one data source, said personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for said multiplicity of envelopes and is matched to individual envelope addresses;   ordering said personalized printing data from said at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings; and   producing said individually addressed sealed envelopes containing personalized printed material matched to individual addresses, said producing comprising:
 printing said personalized printing data, thereby providing a multiplicity of envelope sheets and envelope content sheets for said multiplicity of envelopes; 
 differentiating said envelope sheets and said envelope contents sheets; 
 wrapping said envelope sheets over said envelope contents sheets and thereby creating sealed individually addressed envelopes containing personalized content matched thereto; and 
 gathering and bundling said sealed individually addressed envelopes containing personalized contents matched thereto in said desired distribution sorting order. 
   
     
     
         51 . A method according to  claim 50  and wherein said printing said personalized printing data comprises digital printing. 
     
     
         52 . A method according to  claim 50  and wherein said digital printing comprises digital printing on a continuous substrate. 
     
     
         53 . A method according to  claim 50  and wherein said receiving comprises receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run. 
     
     
         54 . A method according to  claim 50  and wherein said desired distribution sorting order is according to postal code. 
     
     
         55 . A method according to  claim 54  and wherein said desired distribution sorting order is according to the delivery order of a mailman's route. 
     
     
         56 . A method according to  claim 50  and wherein said wrapping comprises wrapping said envelope sheets over contents sheets such that side flaps of said envelope are glued to a surface of said envelope. 
     
     
         57 . A method according to  claim 50  and also comprising, prior to said wrapping, folding said envelope contents sheets, such that said wrapping comprises wrapping said envelope sheets over suitably folded envelope contents sheets. 
     
     
         58 . A method according to  claim 50  and also comprising, prior to said wrapping, placing at least one insert is placed over said envelope sheets, such that said wrapping comprises wrapping said envelope sheets over said envelope contents sheets and said at least one insert.