VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
HSS-10
High-Speed
Automated Mail
Sorting System
Mailpiece identity has to remain connected to the routing decision. The HSS-10 feeds, stabilizes, identifies, and sorts barcode-driven flat mailpieces across ten shingled delivery outputs. Delta-X Trust provides live job status, production tracking, exception visibility, and system-event information throughout the sorting workflow.
Controlled Mail Routing Before Dispatch
Final sorting is not simply a material-handling step. For personalized or sensitive communications, it is one of the last points where a correctly produced mailpiece can still be routed to the wrong destination, mixed into the wrong output, or released without clear production visibility.
The HSS-10 automated mail sorting system connects controlled feeding, vacuum-assisted transport, barcode reading, job-data lookup, divert control, and shingled delivery in one coordinated workflow.
Each identifier is resolved against active job data before the mailpiece is assigned to a destination, while unreadable codes and records without a valid match trigger configured exception logic. By integrating the mechanical, sensing, motion-control, operator-interface, and production-tracking components as one configured system, this creates a controlled handoff from personalized production to downstream collection, batching, or dispatch.
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Secure Card and PIN Mailers
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Government and Citizen Communications
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Healthcare Member Communications
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Loyalty and Promotional Mailers
Controlled Mailpiece Routing
- Barcode-driven lookup against active job data
- Ten configured sorting destinations
- Vacuum-assisted transfer through identification and sortation
- Shingled output for controlled downstream handling
Exception Containment
- Detection of unreadable or unrecognized barcodes
- Configured handling of unresolved mailpieces
- Separation of valid routing decisions from exceptions
- Visible exception reasons for operator response
Live Production Awareness
- Delta-X Trust system and job status
- Real-time speed and production progress
- Production statistics and event visibility
- Line-level visibility from identification through sortation
Watch the High-speed Automated Mail
Sorting System in Action
Watch flat mailpieces being separated and introduced into the transport path, stabilized through the identification stage,
resolved against destination data, and directed across ten shingled delivery outputs.
- Controlled Envelope Feeding: feeder separates and presents approved flat mailpieces individually to support consistent entry into the identification and sorting process.
- Vacuum-Assisted Transfer: transfer module stabilizes each mailpiece as it moves from feeding into the code-reading and data-capture area.
- Inline Barcode Reading: captures the unique linear barcode used to identify the mailpiece and initiate the destination-lookup process.
- Configurable Vision and OCR Capture: capture 2D Data Matrix codes and selected OCR fields in addition to linear barcode data.
- Data-Driven Destination Lookup: the captured identifier is compared with the active job data to determine the mailpiece’s assigned sorting destination.
- Configured Exception Handling: Unreadable codes and identifiers without a valid destination match are flagged and handled according to the approved exception rules.
- Ten-Destination Sortation: executes the routing decision and direct recognized mailpieces toward their assigned outputs.
- Delta-X Trust Production Awareness: Delta-X Trust connects system status, production events, rejection information and job progress to the operator interface.
- Configurable Motion Control: The Emerald 2500 controller coordinates feeding, transfer, identification, divert timing, and delivery across the configured system.
- Operator Interface: The HMI10 provides access to system operation, job awareness, diagnostics and production information.
- System type: Barcode-driven envelope and flat-mailpiece sorting system
- Sort destinations: 10 pockets
- Documented media: #10 envelopes and folded flat packages
- Rated throughput: 10,000+ mailpieces per hour
Process Flow
The HSS-10 controls the complete mail-sorting workflow, from envelope feeding and barcode identification to destination-controlled diversion, shingled delivery, and production tracking. Each stage keeps the physical mailpiece connected to its routing data so recognized items reach their assigned outputs and unresolved pieces remain visible for operator action.
The mailpiece preparation stage separates and stabilizes each envelope before identification. This establishes the controlled position and transport conditions
required for consistent barcode reading and downstream routing.
- Envelope feeding: Introduces #10 envelopes or approved flat mailpieces into the transport sequence.
- Individual presentation: Mailpieces are separated and presented individually for controlled downstream processing.
- Vacuum stabilization: Maintains control of each mailpiece as it moves toward the barcode-reading station.
- Scan-path entry: The transport sequence positions the mailpiece for stable presentation through the identification area.
The identification stage connects each physical mailpiece to its active job data. The captured barcode is resolved against the configured destination rules
before the piece enters the sorting section.
- Barcode reading: Captures the unique barcode associated with the mailpiece.
- Job-data lookup: The captured value is compared with the active production data.
- Destination assignment: A recognized record is converted into a routing instruction for the appropriate sort destination.
- Unreadable-code handling: A barcode that cannot be captured is flagged according to the configured exception logic.
- Unrecognized-record handling: A readable code without a valid destination match remains visible for operator response.
The sortation stage executes the routing decision across ten configured destinations. Each validated mailpiece is transferred, diverted, and
accumulated for controlled removal and downstream handling.
- Bridge transfer: Moves the identified mailpiece into the sorting section.
- Controlled diversion: Divert module directs the mailpiece toward its assigned destination.
- Ten sort destinations: The configured system separates mailpieces across ten defined outputs.
- Shingled accumulation: Delivery conveyors organize sorted mailpieces in a controlled shingled arrangement.
- Output handling: Completed groups remain accessible for removal, counting, batching, or the next production step.
The software and control stage coordinates system movement, routing execution, production status, and exception visibility. Operators can monitor
the active job without separating mechanical activity from the data governing each decision.
- Delta-X Trust tracking: Connects job progress, production activity, and mailpiece-routing events.
- Operator interface: The HMI10 provides access to system status, operating controls, and diagnostic information.
- Motion coordination: The Emerald 2500 coordinates feeding, transfer, identification, diversion, and delivery.
- Production monitoring: Operators can view running status, production speed, job progress, and production statistics.
- Exception visibility: Rejection reasons and system events help operators identify where intervention is required.
Included Technologies
The HSS-10 combines feeding, vacuum transport, barcode reading, motion control, ten-pocket sortation, shingled delivery and Delta-X Trust
production tracking into one configured system.
BSC-1000
Barcode and Data Reading
A user-friendly, fully packaged CCD reader, offering easy integration and several configurations to meet a variety of needs.
DZ Series
Zoned Divert Gate System
Elevate efficiency with the DZ Series Zoned Divert, designed for precise sorting and high-capacity handling in demanding industrial environments.
VSC-1000
Vision Scan System
The VSC-1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.
HYPERVISION 3500
Multi-Layer Vision and Lamination Inspection System
Precision Secure Document Inspection System at Production Speeds — Automated Quality Assurance and NFC Validation for Zero-Defect Manufacturing for Passports.
Advanced 8K Secure Document Inspection System for Maximum Compliance & Security
The HyperVision 3500 sets a new industry benchmark in automated secure document inspection. Engineered specifically for secure credential manufacturing, including passports, national IDs, financial cards, and currency substrates, this advanced vision inspection platform combines 8K ultra-high-resolution optical systems, real-time embedded NFC/RFID chip validation, and fully integrated traceability.
Manufacturers gain unmatched quality control, compliance assurance, and productivity — achieving precision that manual inspection and current systems cannot match.
Passports and Laminations
Government-Issued IDs and Secure Credentials
Currency and Banknote
Enhanced Security & Regulatory Compliance
- Achieve 100% compliance with stringent global security regulations (ICAO, ISO, EMV)
- Real-time embedded chip validation to detect non-conforming units immediately
- Full data transparency with serialized, audit-ready inspection logs
Improved Production
Efficiency
- High-speed operation at 3,500 units per hour reduces inspection bottlenecks
- Automated defect detection drastically reduces manual oversight and rework
- Modular automation design enables easy scaling and integration with existing systems
Superior Quality & Product Integrity
- Detects micro-defects as small as 10 microns, far surpassing manual accuracy
- Ultrasonic sensors verify lamination bonding and thickness consistency
- Robotic handling ensures precise alignment and eliminates variability
- Multi-Layer High-Resolution Optical Inspection
- Real-Time NFC and RFID Chip Validation Module
- Delta-X Vision Intelligence for AI-Powered Defect Detection
- Ultrasonic Sensor Technology for Lamination Integrity
- Fully Robotic Material Handling and Automated Sorting
- Inline Print-and-Apply Labeling with Real-Time Serialization
- Modular Conveyor Layout for Flexible Integration
- End-to-End Data Tracking via Delta-X Tracker
- Inspection Resolution: Defects down to 10 microns
- Throughput Capacity: 3,500 units/hour (1 cycle per second)
- Optical Inspection: Dual-sided, multi-camera array
- Embedded Chip Validation: Live NFC & RFID testing
- Traceability Platform: Delta-X Tracker serialized logging
- Integration Capability: Compatible with ERP/MES systems
- Material Formats: Supports 182 × 405 mm and 186 × 264 mm substrates
- Regulatory Compliance: ICAO, ISO, EMV, and global security standards
Process Flow
The HyperVision 3500 automates every critical step in secure document inspection, providing unparalleled accuracy, reliability, and traceability from initial loading through to final sorting and labeling.
- Walking-Beam Stack Infeed: Efficient, continuous feeding of document stacks for uninterrupted throughput.
- Pick and Place Robots (Passport Covers): Precision handling and accurate positioning of passport covers to ensure inspection readiness.
- Pick and Place Robots (Separator Sheets): Automatic removal and management of separator sheets to reduce manual labor.
- Separator Sheet Outfeed: Efficient recycling and reuse of separator sheets, reducing waste and cost.
- Vacuum Conveyor Alignment: Secure, stable positioning of documents, maintaining precise alignment throughout inspection.
- Optical Alignment Sensors: Real-time monitoring and automatic adjustment to ensure exact document positioning prior to inspection.
- Teslin Side Vision Inspection: Multi-angle, ultra-high-resolution cameras detect scratches, delamination, bubbles, dents, and micro-contaminants.
- Ultrasonic Sensor Assembly: Accurately measures thickness, bonding consistency, and verifies lamination integrity.
- 3D Scanning for Delamination Detection: Advanced sensors quickly detect subtle internal defects, ensuring structural quality.
- Real-Time Defect Flagging: Immediate identification and logging of defects, linked directly to unique serialized product IDs.
- Delta-X Vision Intelligence: AI-powered inspection analysis to detect and classify defects with superior accuracy.
- Automated Defect Logging: Comprehensive, timestamped records generated and integrated instantly with Delta-X Tracker software.
- Automated Turnover Module: Precision reorientation of documents for thorough secondary inspection without compromising speed.
- Outer Surface Vision Inspection: Advanced camera arrays to detect print imperfections, surface scratches, and misalignment as small as 10 microns.
- Embedded NFC/RFID Chip Validation: Real-time resonance frequency and electrical validation, confirming chip performance and placement.
- Registration Mark Printing: Precision application of marks for accurate downstream alignment and traceability.
- AI-Enhanced Inspection Logic: Automatic detection and differentiation between critical and minor defects to prioritize sorting actions.
- Quality Factor Measurement: Ensures embedded chips meet rigorous standards for functionality and compliance.
- Automated Robotic Sorting: Intelligent sorting mechanism immediately diverts defective products for review or reprocessing.
- Stack Elevator Outfeed: Automatic stacking and transfer of approved products for organized, damage-free output.
- Outfeed Product Jogger: Ensures neat, precise alignment of documents, readying them for efficient downstream processes.
- OK/NOK Conveyor System: Clearly distinguishes compliant from non-compliant products, ensuring accuracy and reliability in sorting.
- Inline Print-and-Apply Labeling: Real-time, serialized labeling directly linked to unique inspection records for full traceability.
- Delta-X Tracker Integration: Seamless connectivity with ERP/MES systems, providing comprehensive auditability, real-time reporting, and end-to-end production transparency.
Included Technologies
The HyperVision 3500 incorporates advanced, integrated technologies designed to deliver unmatched precision, secure document inspection, comprehensive real-time traceability, automated defect detection, and NFC/RFID validation — ensuring 100% zero-defect compliance and optimal production efficiency.
BSC-1000
Barcode and Data Reading
A user-friendly, fully packaged CCD reader, offering easy integration and several configurations to meet a variety of needs.
SJ Series
DOD Inkjet
Smart Jet uses industry leading head technology to deliver UV Cured 600 DPI DOD Ink onto any surface.
VSC-1000
Vision Scan System
The VSC-1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.