Efficient card mailing of all order sizes - in offline or online configuration (up to 3,000 cards/hour)

Basic Info

  • TECHNOLOGY: Card Mailing
  • INDUSTRY: Cards
  • SEGMENT: Commercial Cards, Financial Cards, ID Cards


Thanks to MAILMASTER, the mailing of financial, ID, customer loyalty and similar cards is now more flexible and efficient than ever before at speeds of up to 3,000 cards per hour. The system can process multiple small and completely different orders in a single production run – seamlessly and without any interruptions, even in case of order sizes of one. These true Rainbow Deck capabilities offered by MAILMASTER are more comprehensive than any competing mid-volume system currently available.

A range of end-to-end system configurations is available, including card feeding, personalized document printing, along with card reading units, sheet to card matching, attaching, folding, enclosure feeding, envelope inserting, scale and delivery components that can be individually configured for maximum flexibility.

MAILMASTER can change multiple parameters on the fly per mail piece, including quantity of cards, letter template, printer tray, insert(s) and folding type. In addition to the Word-based mail-merge process, the use of pre-rendered PCL, PostScript and PDF files for letter printing is possible – allowing maximum freedom in template design. The system’s new software platform features an enhanced state-of-the-art graphical user interface and guarantees correct matching of the cards with the personalized letter.

The MAILMASTER Machine Control Software is based on Windows 10 and manages the entire data flow and processes of the base system. It features a direct interface for all supported database and datafile formats. The result is a significantly improved performance and stability.

Key Features and Benefits

  • Processes up to 3,000 cards per hour
  • Provides an easy to operate interface based on Windows 10
  • Supports printing based on Word Mailmerge Templates or using pre-rendered PCL, PostScript and PDF files
  • Supports Rainbow Deck applications with changing multiple parameters on the fly
  • Selective enclosure feeding increases versatility of applications


Card Feeding
MAILMASTER can be equipped with up to four card feeders, which can be operated in various configurable selective feeding modes

Card Reading Units
A unique card identifier is read either by means of the magnetic stripe, the chip, or a graphically personalized element such as a barcode or a 2D code. Using the Atlantic Zeiser VERICAM Pro camera system, alternatively extremely reliable OCR-based card reading is supported

Document Printing
In addition to the Word-based mail-merge process, the use of pre-rendered PCL, PostScript and PDF files for letter printing is possible – allowing maximum freedom in template design. When using Microsoft Word-based document printing, fixed text elements, individual personalized data and graphics can be combined for every document. An integrated barcode engine enables on-the-fly barcode generation for sheet-to-card matching. An option for 2D code-based matching is available. Variable data can be supplied in various datafile and database formats

Sheet to Card Matching
Prior to card attaching, the printed letter containing either a barcode or a 2D code is compared with the identification feature of the card

Card Attaching
MAILMASTER allows attaching of up to four cards per document. Attaching is possible to the middle and lower fold of the letter

All conventional types of folds are supported: Z-, C- and V-fold. The folding unit also supports processing a variable number of pages per mail piece

Enclosure Feeding
Up to six enclosures (sheet and/or booklet) can be added to the mail piece

Envelope Inserting
The inserting unit supports a packing thickness (mail piece plus enclosures) of up to 6 mm

Scale and Delivery
A delivery conveyor can shingle up to 600 finished envelopes.
An optional inline scale system with integrated 2D code reader can check whether the sequence of mail pieces is correct. Additionally, it compares the measured weight against the calculated total weight for letter, card(s) and enclosure(s) to ensure each pieces accuracy

Rainbow Option
Multiple orders requiring different mailing setup configurations can be combined to a single production job for highly efficient production. Based on this rainbow deck processing feature, the system can change multiple parameters on the fly per mail piece:
  • letter template
  • simplex/duplex letter printing
  • printer tray
  • location of the card-to-sheet matching barcode
  • quantity of cards per sheet
  • location of every card on the sheet
  • folding type
  • enclosure selection

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