System IQ Inserter Productivity Solution

The Next Revolution in Inserting Optimization

Imagine an inserting system that has the intelligence to slow down when it detects different set sizes, and speed up when there’s an opportunity to optimize production—saving time, money and improving cycle speeds and lowering your cost per piece.

Until now, mail inserters cycled at a fixed speed, or at an operator-selected speed. In both cases, set sizes, material characteristics and paper handling are ignored. This has a negative impact on inserter performance, operator efficiency and productivity. Inserters may run too fast and leave open sections which wastes cycles. Operators may set the machine at a speed lower than the application requires, reducing productivity.

With the Harmonix solution, inserters run more efficiently by adjusting the speed automatically in response to changing set sizes and inserter performance.

On-the-Fly Optimization

Since the inserter machine speed can dynamically increase or decrease to adapt to processing conditions, it can increase speeds when operational conditions are favorable and decrease them when they are not—all on the fly, without the need for operator intervention.

Harmonix can also dynamically change cycle speed to allow for maximum performance calculated against set size distribution. For example, it will increase for small set sizes and decrease when assembling larger set sizes. This allows the input feeder to complete assembling sets, and place material into track, limiting empty track sections sessions.

With Harmonix, mailers can gain greater efficiencies from their existing equipment and ensure that their operations are running at the optimum capacity for each job.

How It Works

When material set sizes are large, the inserter reduces speed to allow sets to complete and present to the inserter, eliminating cycling of empty track sections.

As the inserter is producing product, it analyzes material handling. When conditions are positive speeds increase, when faults are frequent speeds decrease until it achieves optimal performance.