Card mailing system for low volumes

The CASSera is our solution for small and mid-size volume mailings. The arrangement is conceived especially for low budget uses and with a throughput of up to 2000 products per hour, it is also an ideal backup solution.


Card channel


Paper feeding


Form processing



Short description

Low-Budget, heavy Duty

Compact design, robust method of construction, and a long life span distinguish the smallest member of our family CASS. Materials of the highest quality guarantee a high investment security. The CASSera can be used either off-line with a single-sheet feeder, or on-line with a single-sheet printer; and it can be extended for a change of use thanks to its modular design. Setting-up time can be shortened considerably thanks to its excellent operator friendliness.


For all standard card types

  • Standard: ISO IEC 7813*
  • Thickness: 0,18-1,2mm thick*
  • Material: PVC, cardboard, wood, metal, etc.*
  • Special shapes (MC2)
  • Punched cards (e.g. GSM)

Final products

Card mailings

Card channel

Cards are isolated from the input magazines and then supplied to the other processing stations. Magazines from other manufacturers can also be used. In the card canal, all the usual identification procedures are applied for reading the cards to recognise magnetic stripes, chips or other signs, and to compare the information with the data bank. Selective control of the magazines, and different sorts of separation modes, allow for a high flexibility with the job planning.

  • 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)
  • Database-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)
  • Data comparison with given parameters or a data bank
  • Quality controls (e.g., position of chip, magnetic stripe, signature field)
  • Attachment of personalized (on-demand) labels
  • Attachment of preprinted labels

Paper feeding and paper processing

In the on-line or off-line procedure, paper is supplied to the processing stations in the horizontal or vertical format. 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 the on-line condition, the intelligent buffer control ensures that documents are continuously supplied from an added printer. In the off-line mode, the replenishment of the paper supply during the operation of the machine is possible in order to guarantee maximum performance..

  • High-capacity printers produce individualised covering letters in colour or monochrome
  • Database  supported “on demand” printing
  • Buffer for constant cycled feeding
  • Processing preprinted covering letters
  • Single sheet feeder
  • Friction feeder
  • Different feeders for different feeder capacities
  • Insertion of the feeder, and adding of forms in the off-line mode, whilst the machine is running possible
  • Integrated buffer provides for continuous supply of forms from a pre-selected printer

Form processing

Different readings can be used to identify products and to carry out a comparison with other products in order to compare the forms with agreed values. Cards are applied to their carrier documents with a sticky label, or with hot glue. Unlimited positioning and adjustment of the cards offers variable layout possibilities depending on the type of folding. Pre-determined variables such as mismatching, height or fixing can be checked continuously using diverse quality controls and uninterrupted track and trace resources. Different kinds of folding for the folds of the carrier and any subsequent sheets are also available.

  • Identification and comparison with other products or data (e.g., comparison with subsequent sheets, enclosures, cards or data banks)
  • Checking 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
  • a double sided self-adhesive label is detached from a roll and affixed onto the reverse side of the card
  • as the label has different strength adhesives on each side (permanent for carriers/ peelable for cards), the card can be removed cleanly from the carrier without leaving any residue
  • Positioning of the hot glue area is freely selectable (e.g., 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
  • Pick & Place arm for card transport to the desired position on the carrier
  • Fixation of the card by vacuum grip arm
  • Any position and adjustment of the card possibly
  • Up to 2 cards per carrier in the standard version (optionally, and depending on the type of fold, more cards possible)
  • Permanent track & trace and comparison with data banks, or with given parameters, make a mismatch of card and carrier impossible
  • Two fold-cassettes can fold covering letter / documents alternatively upwards or downwards
  • Different fold kinds possibly (C-fold/wrap folding, Z-fold/zigzag fold, half-fold/middle fold)


The inserter accepts one, or several, forms with or without cards from the pre-selected feeder canal. Several forms, also different forms, can be collected together for the same receiver and inserted as a batch (e.g., covering letter with card + an invoice). Furthermore, additional enclosures can be added to the forms, such as flyers, retour forms, terms of trading etc. before they are inserted. With the help of sensors, the processed products are monitored further to guarantee complete track & trace. Faulty arrangements are thus recognised and rejected.

  • One or several forms, with or without card, are taken from the preselected feeder module
  • Several, also different, forms for the same receiver can be collected together in a group before insertion in the envelope (e.g., covering letter with card + invoice)
  • Uninterrupted track & trace to control the processed products
  • Other enclosures (e.g., flyers, brochures, prospectuses, 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 (product-wise programmable) for fully automatic fault 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)
  • Depending on the type of product, friction feeders can also be used
  • Separation of the envelope from below (making it possible to re-fill envelopes during operation)
  • Feed capacity of the enveloping station amounts to approx. 250 mm (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  from C6 to C5 format (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 grip arms
  • Envelope strength up to 6 mm (also thicker upon 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 flap moistening or via hot glue
  • Optional letter turnover module for the filing / issue of envelopes with the address “face-up” or “face-down” (written side on top or below)

Special features

  • Compact design and robust method of construction
  • Compatibly with card magazines of other manufacturers
  • Modular design – therefore upgradable for higher volumes
  • Long life span and high investment security
  • 24/7 production mode

Technical specifications

ThroughputUp tp 2.000 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 placement
PaperMin. 70 g/m², max. 120 g/m² (other upon request)
Temperature/HumidityOptimal: 20-25°C room temperature, 60 % relative humidity

“With the CASSera, we are proud to offer the reliability of a high performance machine at a price of a low budget mailing system. ”

Ronald Düe, Senior Vice President Sales


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