Mailing system for mid-size volumes

The CASSilo is a highly adaptable, tailor-made mailing system for the production of individual and personalised card mailings in the smallest batch size and the highest variance. From a choice of more than 80 functions, components can be put together and be integrated into modules.


Card channel


Paper feeding


Carrier processing




Final processing

Short description

Variance in top form

The CASSilo is a highly adaptable, tailor-made mailing system for the production of individual and personalised card mailings in the smallest batch size and the highest variance. From a choice of more than 80 functions, components can be put together and be integrated into modules. This results in a nearly limitless number of application possibilities. The customer determines the working spectrum of his CASSilo system. The extent of the system`s performance includes a fully automatic production at a rate of up to 3000 cards per hour with complete track & trace security, the shortest setup times and the maximum operator friendliness. The intelligence of the machine supervises and controls the product as well as the actions of the operator. Thus, the CASSilo system guarantees the highest security with the greatest efficiency and economy.


For all customary 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

CASSilo Kartenkanal

Card channel

The individual functions in the card channel make it possible to grasp the whole extent of the card. Optical or digital information is processed; personalizing, coding and labeling can be carried out, sorting or grouping can be undertaken. The modularity of the card channel allows nearly every configuration of the functionality which the customer may require. Software and hardware can be extended and upgraded at any time.

  • 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)
  • Verification
  • Data comparison with given parameters or a database
  • 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 perzonalisation via laser printer, inkjet or thermo transfer
  • Personalization of cards of different materials (e.g., wood, metal, cardboard, plastic, etc.)
  • Buffer star for the short-term temporary storage for up to 60 cards
  • Sequencer for the intelligent (pre-)assortment of different cards or card designs
  • Card kiosk for the safe (temporary) storage of several thousand cards (also of different designs)
  • Sorting, storing and grouping processes as per the first-in-first-out principle or cycled
  • Integration of input and output magazines for the picking out of cards for an individual subsequent treatment
  • Shortened production times by not losing time for setting up

CASSilo Papierzuführung

Paper feeding

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.

  • High-capacity printers produce individualised covering letters in colour or monochrome
  • Database 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, whilst the machine is running 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 stack or from a roller
  • Integrated loop control as a form buffer in the online 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

CASSilo Carrier-Verarbeitung

Form processing

The form supply from the upstream feeder modules takes place cyclically. Sensors constantly monitor the covering letter on the way to the following modules. They allow a complete track and trace, and they prevent any possible mismatch. The form processing exists essentially of the form reading, the labeling station for the gummed labels, the label feeding station, and the folding unit. The folded or unfolded forms can either be collected together into groups, or be handed over to a letter storage box, an inserting machine file tape, or to another processing or packing system. Furthermore the forms can already be transported to a storage area before the folding unit.

  • Identification and comparison with other products or data (e.g., comparison with subsequent sheets, enclosures, cards or databases)
  • 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
  • Position of the labels can be freely selected (e.g., sticky tape not in the signature field)
  • Position of the labels can be varied selectively within a job (without manual modification)
  • 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 gripper arm
  • Any position and adjustment of the card possible
  • Up to 4 cards per carrier in the standard version (optionally more cards possible, depending on the fold type)
  • Permanent track & trace and comparison with database, or with given 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
  • 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)
  • 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

CASSilo Kuvertierung


The inserter processes forms in the DIN-A6 to DIN-A5 format (or DIN-A4 prefolded) and inserts them in envelope formats C6 to C5. Special formats are possible on request. During the inserting process, enclosures can be added permanently or selectively from different inserting stations. The standard module can integrate up to 4 enclosure stations. Further stations are possible on request; thus  the system can theoretically be equipped with any number of enclosure stations. All collected products of a consignment are put into an envelope and then sealed securely.

  • One or several forms, with or without card, are taken from the preselected feeder module
  • Several, even different, forms for the same receiver can be collected together in a group before insertion in the envelope (e.g. covering letter with card and invoice)
  • Uninterrupted track & trace to control the processed products
  • Other enclosures (e.g., flyers, brochures, leaflets, terms and conditions etc.) can be added to a mailing in enclosure stations
  • Infinitely variable setting of the enclosure stations for different dimensions using quick fasteners, fixed stops and millimeter scales
  • Thickness control in every single enclosure 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)
  • 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 (e.g. 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; also 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 recognition in every enclosure 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 grip arms
  • Envelope strength up to 12mm (also greater on request)
  • Product recognition avoids filling wrong envelopes by operators (e.g. via horizontal 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 flip over module for the filing / issue of envelopes with the address “face-up” or “face-down” (written side on top or below)

CASSilo Nachverabeitung

Final processing

In the finishing stage, 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 finishing 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. To mention a few of them:

  • Selective rejection of faulty 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 a Last-Pull function (via previous product reading or by data comparison with the input file)
  • Weight examination of the final mailing
  • Rejection 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 from above or below possible

Transport notes, sender’s address, courier data, advertising messages and other personalized 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, batch kicker 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

  • Up to 12 card input magazines
  • Compatible with magazines of other manufacturers
  • More than 80 functions to combine
  • Fully automatic job setup
  • 24/7 production mode
  • Modular design for various applications
  • 1-4  cards per form are standard, 8 cards possible
  • Selective processing for all machine sections via control code or input file

Technical Specifications

SpeedUp to 3.000 cards/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
Tolerance+/-1mm 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 our CASSilo we are able to offer a flexible mailing system that is equipped for the tasks of tomorrow. The CASSilo combines flexibility, reliability and performance.” Tobias Pomarius, deputy production manager.


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