RP Series
Rotary Pick and Place Series
Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
MA-500
Secure Card Mailer
Match & Attach
System
The MA-500 is engineered to match personalized cards to letter or legal-sized carriers at production speed, while maintaining controlled placement, real-time validation, and workflow flexibility. It supports a wide range of card and carrier formats, including non-standard product dimensions, with consistent affixing accuracy.
High-Speed Card Matching Without Losing Product Control
Secure card fulfillment depends on more than attaching a card to a carrier. The line must confirm that the right card is matched to the right personalized document, placed accurately, folded correctly, and tracked through the production sequence.
The MA-500 is designed for high-volume card issuance, personalization bureau, and direct mail environments where throughput, product flexibility, and data integrity must work together. The system can process more than 350,000 cards per day, matching personalized cards to carriers with consistent placement accuracy.
Quick workflow changeover allows producers to support different carrier sizes, card formats, fold styles, and fulfillment requirements without forcing every job into a standard template.
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ID Cards & Driver’s Licenses
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Credit, Banking & ATM Cards
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Membership & Loyalty Cards
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Healthcare & Life Science
Consolidate Card Fulfillment
- Combine output from multiple card personalization lines
- Reduce offline attaching and manual transfer points
- Support high-volume direct mail and card issuance workflows
Expand Carrier Flexibility
- Process letter, legal, and custom carrier dimensions
- Support standard and non-standard card formats
- Run portrait or landscape card placement
- Support half fold, Z fold, C fold, and barrel fold configurations
Protect Match Integrity
- Match cards to personalized carriers in real time
- Maintain ±0.5 mm affixing accuracy at up to 16,000 PPH
- Track, validate, and report production data end to end
- Remake rejected products on the fly without stopping the line
Watch the MA-500 Secure Card Match
& Attach System in Action
- Speeds up to 16,000 PPH
- Card affixing accuracy of ±0.5 mm in portrait and landscape orientation
- Carrier fold support for pre-fold, inline, half fold, Z fold, C fold, and barrel fold
- Real-time data matching, tracking, validation, and end-to-end reporting
- On-the-fly product remake to keep production in sequence without stopping
- 100% servo-driven architecture with digital brushless servo motors
- Remote virtual machine platform and system diagnostics
- Card reading support for OCR, barcode, magstripe, and contactless formats
- Carrier reading support for OCR and barcode
- Front, back, and plow folding configurations Integration with Delta-X Trust for production tracking, validation, reconciliation, and reporting
- Designed for 24/7 production environments with quick change between workflows
- Segment: Cards
- Primary function: Card & carrier matching with data validation
- Maximum speed: 16,000 PPH
- Daily capacity: More than 350,000 cards per day
- Card affixing accuracy: ±0.5 mm
- Orientation support: Portrait and landscape
- Fold types: Pre-fold, inline, half fold, Z fold, C fold, barrel fold
- Drive architecture: 100% servo driven with digital brushless servo motors
- Data handling: Real-time matching, tracking, validation and end-to-end reporting
- Remake capability: On-the-fly product remake while maintaining production sequence
- Operator requirement: 1 operator + 1 person reloading + 1 person on delivery
- Diagnostics: Remote virtual machine platform and system diagnostics
- Uptime: 95% or better
Process Flow
The MA-500 controls the full card-to-carrier workflow, from carrier feeding and registration to card matching, affixing, inspection, folding, and delivery. Each step is designed to protect match accuracy, placement control, and finished mailer integrity at production speed.
The carrier preparation stage establishes the position, alignment, scoring, and adhesive pattern required before card placement. This gives the MA-500 a controlled foundation for accurate matching, affixing, folding, and downstream delivery.
- Carrier feeding: Introduces letter, legal, or custom carriers into the MA-500 transport sequence.
- Carrier registration: Positions each carrier before scoring, glue application, card attachment, and folding.
- Vision inspection: Verifies carrier presence, orientation, and critical printed or registration features before the carrier moves downstream.
- Scoring and slitting: Applies the required score marks or preparation features for the selected fold configuration.
- Fugitive glue application: Applies temporary adhesive points to secure the card while allowing clean end-user removal.
The card matching and affixing stage confirms card identity, matches the card to the correct carrier, and verifies placement after attachment. This is the core control point for protecting personalized card integrity before the product moves into finishing.
- Card feeding and data read: Feeds cards into the system and reads required card data using OCR, barcode, magstripe, or contactless technologies.
- Data read and write: Supports required card and carrier data validation within the production workflow.
- Pick and place robotics: Transfers and positions cards for controlled attachment to the prepared carrier.
- Card attachment: Affixes the matched card to the correct carrier in the required position and orientation.
- Placement inspection: Verifies card position after attachment to support ±0.5 mm placement accuracy.
- Diverting: Removes mismatched, rejected, or non-conforming products from the production sequence.
The finishing stage applies required labels, verifies placement, completes the selected fold format, and delivers the finished carrier for downstream mailing, fulfillment, or pack-out. This keeps critical finishing steps inside the controlled production flow.
- Label application: Applies required pressure-sensitive labels, activation labels, or program-specific labels where required.
- Label placement inspection: Verifies label presence and position before the carrier advances.
- Folding options: Supports pre-fold, inline, half fold, Z fold, C fold, and barrel fold configurations.
- Conveying: Maintains controlled product movement through the folding and delivery sequence.
- Delivery: Transfers finished carriers for downstream mailing, fulfillment, or pack-out.
Delta-X Trust connects production activity, validation events, inspection outcomes, exception handling, remake logic, and reporting across the MA-500 workflow. This gives teams a stronger production record and clearer control over card-to-carrier fulfillment.
Real-time matching
- Connects card and carrier data during production to protect match integrity.
Tracking and validation
- Tracks product status through the MA-500 workflow and validates critical production events.
Camera scanning
- Supports inspection and verification logic tied to carrier, card, label, and placement control.
End-to-end reporting
- Provides production records for job review, reconciliation, and operational accountability.
On-the-fly remake
- Supports remake of rejected products while helping maintain production sequence.
Remote diagnostics
- Supports system visibility, troubleshooting, and production support.
Included MA-500 Technologies
The MA-500 is built around coordinated production control. Feeding, registration, data reading, vision inspection, gluing, affixing, folding, diverting, and Delta-X Trust work together to keep each card, carrier, and production event aligned through the full fulfillment sequence. This helps card issuers, personalization bureaus, and direct mail providers manage high-volume card programs with greater accuracy, flexibility, and operational confidence.
AL Series
Powered Autoloader
Maximize productivity with the AL Series Powered Autoloader. Designed to extend loading capacities and reduce manual reloading for high-speed applications, ensuring continuous operation and 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.
UVL-7550
LED UV Curing Technology
The UVL-7550 integrates high-power LED UV lamps for superior, high-speed, single-pass drying and curing applications. Offering an eco-friendly solution with significantly reduced power consumption compared to traditional systems.
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.
ABM
Automatic Product Alignment
The ABM module features modern servo motor technology and a robust construction, making it ideal for various applications, including feeding plastic cards, labels, and product samples.
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.
BF-100
Back Fold Module
An ultra-lightweight alloy folding attachment. The BF-100 delivers unmatched productivity for four and six-corner folding tasks.
MFF-120
Front Fold Module
Streamline your production with the MFF-120 Front Fold Module, designed for high-speed, precise folding of various products at right angles.
PF50-90
Plow Fold Module
The PF50-90 Plow Fold Module integrates seamlessly into production lines, offering both left and right folding configurations.
HSL-60
High-Speed Label Applicator
The HSL-60 is a highly versatile module that applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications.
DL Series
Shingled Delivery Transport
Discover the DL Series Shingled Delivery Transport, designed for efficient and ergonomic conveying of diverse printed materials.
