CASS C8000

Mailing system for maximum performance.

With a speed of up to 8000 cycles per hour, the CASS C8000 is our strongest mailing system. Whether as a hybrid multi-talent or as an individually configured specialist with the option for later enlargement: customer wishes can always be moved adaptably and reliably with the C8000. The user-friendly operation of this machine, and its enormous versatility, round off the profile of this performance giant.



Card channel


Paper feed


Form processing




Final processing

Short description

Speed and flexibility at the highest level

Always there at work where the demands are the highest: with the most powerful mailing system of our family CASS you do not need to make any compromises with your card processing. Quickness, flexibility and the highest product security all guarantee an efficient processing of your mailings. High volume throughputs as well as numerous small batch sizes are processed by the C8000 with the highest precision. Moreover, the system is modular and easily extendable. As a hybrid version there is also the possibility available to place individual cards separately within a job on different X and Y axis without big modifications!


For all standard card types

  • Standard: ISO IEC 7813*
  • Strength: 0.18mm to 1.2mm*
  • Material: PVC, cardboard, wood, metal, etc.*
  • Special forms (MC2)
  • Punched out cards (e.g., GSM)

End products

Enumeration of the end products

Card channel

From as many input magazines as you may want, cards are isolated by a vacuum system and are fed into the processing cycle. During this procedure, and following a scanning of all standard data carrying systems, a comparison is made with the data bank to allow gapless track-and-trace and to verify the identity of the products. In addition, the intactness of the cards is guaranteed at this point by optical quality controls. Extensive processing options like personalisation, sorting, grouping or temporary storage facilities allow the optimum preparation to the subsequent treatment of the cards.

  • Unlimited number of input magazines (and fully compatible with many types of magazines)
  • Vacuum separation of cards
  • Different sort modes (e.g., flip-flop)
  • Selective magazine control
  • Individual card arrangements (also for different card designs/card types)
  • Data bank supported process
  • Reading of all known data carrier systems presently on the market possible (e.g. magnetic stripe, RFID, chip, bar code, and QR code)
  • Digital or optical reading via OCR cameras
  • Recognition of different font types and sizes and different alphabets and characters
  • Reading specific security features possible (e.g. UV ink, infrared signs, phosphorescent elements)
  • Verification
  • Data comparison with given parameters or a data base
  • Quality controls (e.g. position of chip, magnetic stripe, signature field)
  • Attachment of personalised (on-demand) labels
  • Attachment of preprinted labels
  • Attachment of security labels (e.g. scratch-off, seals, holograms, kinegrams, activation stickers)
  • Card personalisation via laser printer, inkjet or thermo transfer
  • Personalisation of cards of different materials (e.g. wood, metal, cardboard, plastic, etc.)
  • Buffer star for temporary storage of up to 60 cards
  • Sequencer for smart (pre-)sorting of different cards and designs
  • Card kiosk for save buffering of several thousand cards in different designs
  • Sorting, buffering and grouping on a FIFO (first-in, first-out) basis or by clocking
  • Integration of input and output magazines to reject cards, allowing for individual processing
  • Short production cycles due to no time consuming machine setup

Paper feeding and paper processing

In the online or offline procedure, paper is supplied to processing in the horizontal or vertical format as a single sheet or as fan-fold paper. Preprinted covering letters, or personalised documents, are processed to be brought together afterwards with one or several cards. Alternatively, the system can be also equipped with several feeding modules at the same time. In addition, a mixture of endless and single sheet processing is possible. For special applications, a combination of different modes (online /offline or sheet/fan-fold paper) can be set up.

  • High-capacity printers produce individualised covering letters in colour or monochrome
  • Data bank supported “on demand” printing
  • Buffer for constant cycled feeding
  • Processing preprinted covering letter
  • Single sheet feeder
  • Friction feeder
  • Different feeders for different feeder capacities
  • Insertion of the feeder, and adding of forms in the offline mode while the machine is running is possible
  • Integrated buffer provides for continuous supply of forms from a preselected printer
  • Form sets can be processed in one-up or two-up procedure
  • Supply of fan-fold paper from a high-level pile or from a roller
  • Integrated loop control as a form buffer in the on-line procedure

Special friction feeders for special formats can be integrated (e.g. punched forms with eurohole hangers, and much more)

  • Concurrent implementation of different modes (Online / offline or single sheet / fan-fold paper) possible
  • Alternate supply of paper from two channels possible

Form processing

After an additional check of all documents, and a check for mismatches, labels or hot glue are applied to the carrier to which the cards shall later be applied. With an optional hybrid function, the position of the X-and Y-axis for every card can be fixed individually by way of the database without modifying the machine. This allows maximum layout flexibility within a job. Forms are folded, provided with cards, folded again if required, and finally checked by various control mechanisms for correctness. Optionally, the system can be equipped with many additional modules and special functions. These include, for example, label printers for security labels, or inkjet printers for the printing of further information or for example of PIN numbers.

  • Identification and comparison with other products or data (e.g., comparison with subsequent sheets, enclosures, cards or database)
  • Check of the carrier layout (offset verification)
  • Different systems for the recognition of identification signs (e.g. linear bar codes and QR code scanners, Datamatrix scanners, OCR cameras, video cameras)
  • Information from reading the covering letter can determine which selective functions should be chosen for further processing
  • Double-sided sticky labels for applied cards are processed as “a tape” from the roll
  • Minimum material consumption by exact cutting of desired label size
  • Smallest possible glued area for comfortable later removal of cards
  • Positioning of the hot glue area is freely selectable (i.e. not in the signature field)
  • Position of the hot glue area can be varied selectively within a job (without manual modification)
  • Glue can be applied as blobs or as stripes
  • Two folding units in standard configuration (1 pocket folder, 1 plough folder)
  • Pocket folder for folding before card is affixed
  • Plough folder for folding after card has been affixed
  • Different folding types in combination with different card affixing positions possible
  • Different kinds of folds possible (C-fold / wrap folding, Z-fold / zigzag fold, half-fold / middle fold)
  • Cards are selected according to the covering letter
  • Card attachment via traversable vacuum stamps
  • Fixation of the card by vacuum grip arm
  • Any position and adjustment of the card possible
  • Up to 4 cards per carrier in the standard version (depending on the fold type more cards are optionally possible)
  • Permanent track & trace and comparison with databases, or with specified parameters, make a mismatch of card and carrier impossible
  • Height control checks the presence of the card after its fixation on the carrier
  • Air jet under the card checks the adhesion of the card to the carrier
  • Optional flip-over module for the subsequent treatment of the folded covering letter / documents
  • Address on covering letter face-up or face-down (written side either above or below)

Optional additional modules available for the system, e.g.:

  • Ink jet printer for the print of additional information, security information or PIN numbers
  • Labeler for security labels (e.g. to provide a scratch patch over a printed PIN, or to protect applied cards with a security label against unauthorized removal)
  • And much more


The inserter processes forms in the format DIN-A6 to DIN-A5 (or DIN-A4 prefolded) and inserts them in envelope formats C6 to C5. Special formats are possible on demand. During the inserting procedure, enclosures can be fed from different supplement stations, either continuously or selectively. In the standard module, up to 2 or 4 supplement stations can be integrated. Other stations are possible on inquiry. The system can be equipped with as many supplement stations as may be required. All accumulated products of a mailing are fed into an envelope and afterwards closed securely.

  • One or several forms, with or without card, are taken from the preselected feeder module
  • Several, possibly different forms for the same receiver can be collected in a group before insertion in the envelope (e.g. cover letter with card & invoice)
  • Gapless track & trace to control the processed products
  • Other enclosures (e.g., flyers, brochures, leaflet, terms and conditions etc.) can be added to a mailing in enclosure stations
  • Infinitely variable setting of the supplement stations for different dimensions using quick fasteners, fixed stops and millimeter scales
  • Thickness control in every single supplement station (programmable for each product) for fully automatic error and double-sheet control with every feed cycle
  • Single stations (one station per different enclosure) or tandem mode (filling of two stations with the same enclosure for higher sort and issue capacity)
  • Enclosures are isolated normally from below by vacuum and afterwards are drawn off from the pile by a gripper arm
  • This technology is suitable for thin enclosures (i.e. flyers) or prefolded products with closed edge on the sorting side
  • Capacity of the enclosures in the standard configuration approx. 250mm
  • Enlargement or extension possible using High-Capacity feeders
  • Steady filling or refilling of enclosures possible; even during operation
  • Depending on the type of product, friction feeders can also be used to separate enclosures with open edges
  • Further, additional feeders can be integrated to seperate special enclosures and catalogues/booklets
  • Product identification in every supplement station (e.g. linearly bar code or QR code scanner, datamatrix scanner, OCR reading)
  • Comparison with data in the input file makes sure that wrong fillings are avoided, and all documents receive the right enclosures
  • Separation of the envelope via vacuum from below
  • Feed capacity of the enveloping station amounts to approx. 250mm (optionally extendable with High Capacity feeder for up to 2,000 envelopes)
  • Infinitely variable for different envelope formats (by quick fasteners, fixed stops and millimeter scales, individual formats on inquiry)
  • Sensors check the orderly opening of the envelope flap after its selection
  • Processing of all automation compatible envelopes (special envelopes, e.g., made of plastic, with open address windows, without address windows, etc., possible on request)
  • Inserting the amassed products (card carrier, documents, enclosures, etc.) occurs using insertion finger in envelopes opened by vacuum gripper arms
  • Envelope strength up to 12mm (also greater on request)
  • Product recognition avoids filling wrong envelopes by operators (e.g. via linearly bar code and QR code scanner, datamatrix scanner, OCR reading, or logo recognition)
  • Matching of mailing / shipment arrangement and envelope
  • Sealing of the envelope by water and flap moistening or via glue
  • Optional letter turnover module for the filing / issue of envelopes with the address “face-up” or “face-down” (written side on top or bottom)

Final processing

In postprocessing, card carriers and sealed envelopes in the formats C6 to C5, which have been already processed can be checked, controlled, optimized for postage charges, sorted, and be packed before the actual mailing takes place. Some modules which are used in this postprocessing stage follow the four-eye principle and serve as a final control of the dispatched product. For this reason, the sealed envelopes are guided through different modules in which the shipment is checked by means of sensors and supervised up to the depositing area. Thanks to the modular structure, various modules and functions can be integrated. A selection:

  • Selective rejection of erroneus mailings (e.g. too light, damaged, etc.), mailings which should be processed by hand, or mailings which should not be delivered by the direct courier service
  • Separation of mailings by one Last-Pull function (via previous product reading or by data comparison with the input file)
  • Weighting of the final mailing
  • Discard tray for mailings with weight divergences for manual examination regarding completeness
  • Identification of sealed envelopes for the comparison of the read information in the address field via bar code or QR code scanner, datamatrix scanner or OCR reading
  • Cameras for the recognition of logos and other visual images
  • Reading of contactless RFID chips in the sealed envelopes via aerial (also possible: “locking” of the chip for protection against unauthorised reading during transit)
  • Readings are possible from above or below

Transport notices, sender’s address, courier data, advertisings and other personalised data can be printed on the closed envelope (e.g. via inkjet printer)

  • Optional application of labels after enveloping (e.g. security label over the sealing of the envelope flap, address label with courier or stamping information)
  • Preprinted or individually printed labels

Optional integration of standard postage franking machines for prepaid postage charges (by embossing or inkjet printer)

  • Individual sorting of the closed envelope (e.g. according to postal code, country, region, courier, etc.)
  • Grouping of the mailings (e.g. by means of colour marking on the envelope edge, batchkicker for lateral moving of an envelope on the conveyor belt, or dividing cards)
  • Sorting and grouping according to job default or selectively by information from an input file
  • Selecting out single envelopes for a later special treatment
  • Packaging of the envelope for the collective dispatch after previous grouping possible
  • Banding of an envelope pile with a banderole from paper or plastic
  • Crossband banding for particularly manipulation resistant collections
  • Postal boxing system for the fully automatic filling in storage boxes
  • Application of personalised forms (e.g. retour forms / receipt acknowledgement etc.) on the closed envelope
  • Pre-personalised or printed forms
  • Comparison of form and envelope by integrated reading before bringing together

Special features

  • 1-4  cards per form are standard, 8 cards possible
  • Compatible with card magazines of other manufacturers
  • Free card positioning / fixing possible (within a job)
  • Fully automatic job programs
  • 24/7 production modes
  • Modular design for different applications
  • Selective processing for all machine sections via control code or input file

Technical specifications

ThroughputUp to 8.000 products/hour
Operators needed1
Power supply3ϕ, 400v 50/60Hz
Compressed airMin. 8 bar, ca. 300 l/min. (free of oil and water) ISO 8573.1 class 2 and ISO12500
Precision+/-1mm tolerance for card positioning
PaperMin. 70 g/m², max. 120 g/m² (other upon request)
Temperature/HumidityOptimal: 20-25°C room temperature, 60 % relative humidity

“High-Speed Processing with the highest level of precision. Our C8000 is the master athlete among our mailing systems. Even though it’s fast as lighting it still offers maximum processing security.”

Dimitri Reichert, Software Engineer


Do you have any questions? We are happy to talk to you at any time. Write us a message or just call us. We look forward to your inquiry!

Otto Künnecke GmbH
Bülte 1
37603 Holzminden


Fon +49-5531-9300-888