Card Mailing System

Mühlbauer’s in-house developed card mailing system CARDMAIL 6000 is a fully automated, cost-effective solution for card delivery but also for pure paper mailing. It is a modular solution, able to work with various offline carrier printers or with individual preprinted letters separated/supplied by an autoloader system. Cards can be identified before the attachment in different ways. Due to its standardized modules the CARDMAIL 6000 offers a very competitive price with minimum footprint and highest yield. With a throughput of up to 4,500 envelopes / hour, the CARDMAIL 6000 is an ideal solution for high volume production.

Key Features

  • Industrial designed in-line mailing system for card mailing and finishing
  • Highly modular and flexible system design
  • Latest technology and know-how standards
  • Friction and scratch free card separation by vacuum
  • Security locks on all module doors as standard
  • Various integration of in-line quality control features
  • MCES including MB Product Designer
  • INCAPE ready


Productivity / Process Units

The system consists of:

  • Card feeding from input shaft / magazine
    • 500 cards per shaft / magazine
    • Double card detection
    • Card position/rotation check (optional)
    • Multiple input units (up to 15 shafts / magazine) (optional)
  • Autoloader for offline printed carrier sheets
    • Stacker for up to 3000 preprinted sheets
    • Active antistatic unit (optional)
  • Automated online card identification / matching modules
    • Magstripe reader (HiCo, LoCo)
    • Chip reader (contact, contactless, dual interface)
    • Vision system for optical data
    • Barcode reader (carrier-card-matching)
    • Card flip unit
  • Card affixing unit - up to 6 cards per carrier
    • Adhesive tape dispenser (endless or precut tape)
  • Cards-on-carrier verification
  • Carrier sheet collecting
  • Multi-folding unit
  • Enclosure station - up to 12 enclosure feeder
    • Double sheet detection (optional)
    • Barcode reader (optional)
    • Vision system for enclosure matching (optional)
  • Envelope inserting, humidification and closing unit
    • Check weigher (optional)
    • Envelope reject (optional)
    • Envelope flip unit (optional)
    • Barcode reader for envelope (optional)
    • Vision system for address verification (optional)
  • Envelope sorting (optional)
  • Output conveyor
  • Operator / service / administrator identification by biometric verification (optional)


Technical Data

  • Card format: ID-1 (CR80)
  • Card materials: PC, PVC, ABS, PET, PETG, others on request
  • Paper formats: A4, A5 US letter, US legal according to ISO 216 (other on demand)
  • Paper weight: 70 – 120 g/m²
  • Envelope formats: C5/6 (DIN long), C5, C6 No.9, No.10, A10
  • Folding types: C- / Z- / V- fold or double-parallel-fold
  • Card / letter matching: Chip, magnetic stripe, optical (vision or barcode reader)
  • Interface: Ethernet
  • Throughput: Up to 4,500 envelopes / hour; depending on process and applied cards on carrier
  • Environment conditions:
    • Room temperature: 23°C; +/- 3°C
    • Humidity: 50%; +/- 10%

Mühlbauer Group
Josef-Mühlbauer-Platz 1
93426 Roding Germany

Phone: +49 9461 952 0
Fax: +49 9461 952 1101

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