What does it do?
Evolution is a multi-format mail inserter for mid-level volume mailers from US manufacturer BlueCrest. It is suited to both transactional and direct mail operations, with automation allowing “quick and easy” switching from one application to the other, BlueCrest says.
BlueCrest was spun off from Pitney Bowes in July 2018 to concentrate on ‘industrial’ mailing lines and BCC mailing and sorting software, plus the rebadged HP PageWide inkjet web presses, that it calls IntelliJet, and the rebadged Kyocera TaskAlfa Pro 15000 sheetfed inkjet press called EvoluJet.
Evolution was developed inhouse by BlueCrest, but uses some of the automation technology from high end mailing lines. It sits in the middle of BlueCrest’s range of mail inserting platforms, with EPIC above and MSE, Rival and Velocity below in terms of features and functionality.
When was it launched and what are the target markets?
The base model was launched in the US in 2020 and has seen a few updates since to decrease setup times and occupy a smaller footprint. It has only been sold in Europe comparatively recently – it supports US and European letter formats.
BlueCrest says: “A flexible, multi-format inserter, the Evolution is ideal for both mid- and high-volume mailers who run high page-count jobs, short-run jobs, or need extra capacity during peak times, without sacrificing accuracy or integrity. The built-in automation and compact work cell make it easy to operate, even for less experienced operators.”
How does it work?
David Jefferies, BlueCrest’s UK-based marketing director for EMEA, says: “Evolution brings high-end automation and flexibility to a mid-range platform. The machine processes all European letter sizes and uses BlueCrest’s Direct Connect operating system running file-based processing for full process integrity (reading technology options include OMR, Barcode, 2D, and OCR). Evolution is modular and expandable, and can be configured with between three and 18 feeders.
A portrait to landscape module adds flats capability. Mail traying can be automated by an optional cobot arm called Ottomate Trayer, which moves finished mail from the inserter into a mail tray and places it on a conveyor.
“Thanks to a simple, easy-to-use system interface, mailers can reduce labour hours and increase production capacity,” says Jefferies. “In addition, Evolution runs a file-based processing system to help achieve the highest mail piece integrity in the industry. Such automation is typically associated with higher-end, higher-cost systems.”
The line is automated from input to output, accepting roll-fed or cut-sheet pages (single or dual) and ending with sealed envelopes. Many adjustments that used to take time manually – fold plate, buffer, side guides, insert engine and output – are automated through job setup from the operator screen. Setups are repeatable for regular or repeat work.
However, the setup of insert and envelope feeder side guides remain manual to accommodate the size and thickness variations that come with paper stock changes.
Software options include on-board system diagnostics; the ability to integrate and monitor systems across multiple locations, manifesting and postage accounting solutions; end-to-end tracking; automated re-prints; predictive analytics and maintenance tools.
There’s a choice of three optional inline printing systems. Print+ Messenger is an inline inkjet for plain white envelopes. It runs at 26,000 pieces per hour (pph), with full-colour, fully variable text and images, printed inline within the inserter work cell. The fast-drying dye ink doesn’t need a special drying unit.
Print+ Response is an inline unit that prints monochrome or full-colour 600x600dpi images on plain envelopes or inserts at speeds up to 22,000pph.
Print+ Statement is a full inline document printer for short-run jobs or reprints, running inline with the work cell. The BlueCrest software handles the process of sending reprints to the print unit. It’s a 1.5m long unit that prints 40-160 simplex or duplex documents per minute. BlueCrest’s Output Manager software handles colour management with ICC profiles.
How fast is it?
Evolution runs at up to 12,000 cycles per hour (cph) on a tri-fold letter, 10,000cph for half-fold or 8,000cph for flats. The input modules process roll-fed documents up to 72,000 pages per hour, or cut sheets at 50,000pph.
What’s the USP?
Jefferies says: “The high levels of setup automation, changeover speed and minimal footprint, which we believe is the smallest for its class, deliver high mail pieces per square metre. A single operator can run the highly ergonomic work cell.
“There’s tremendous flexibility to process more short-run, quick-turnaround jobs and minimise machine idle times, yet be equally efficient running high-speed, high page-count applications.”
How easy is it to use?
Would existing Pitney Bowes/BlueCrest operators find it easy to cross over?
“Evolution is very easy to operate,” says Jefferies. Typically, new users are up and running quickly with minimal training.
“Automated setup and visual on-screen error alarms lower the need for operator interventions. Any operator, whether familiar with a BlueCrest inserter or not, can immediately turn their hand to an Evolution.”
How are the machines sold and supported in the UK?
“Machines are sold directly in the UK and supported by our nationwide network of qualified service engineers,” Jefferies says. “Training is available in our Liverpool-based Technology Centre or at the client site.”
The first UK user came in 2023. “We have just sold our 100th Evolution platform worldwide, Jefferies says. Around two systems a month from our manufacturing facility are now an Evolution.”
What does it cost?
BlueCrest Evolution is priced from £250,000 upwards, depending on configuration.
SPECIFICATIONS
Speeds 12,000 cycles per hour for tri-fold letters; 10,000cph for half-fold; 8,000cph for flats
Feeders Up to 18, friction and rotary, with double-feed detection
Total pack thickness 13mm for tri-fold, half-fold or flats
Price From £250,000
Contact BlueCrest www.bluecrestinc.com, info@bluecrestinc.com
ALTERNATIVES
KAS Paper Systems
KAS makes three envelope inserters, of which the top Mailmaster Ascent with its 8,000 envelopes per hour throughput is probably the nearest equivalent to the BlueCrest Evolution. This has semi-automatic setup and changeovers with quick change features. It can feed, accumulate and insert flat for C4, or fold and insert for DL and C5, set by reading codes on the documents. More flexibility is available with the camera, which reads OMR, 1D and 2D barcodes. Four insert stations can handle a variety of material including single sheets, card, reply envelopes, pre-folded items, stapled sets, CDs and booklets.
Contact KAS Paper Systems 01582 662211 www.kaspapersystems.com
Quadient
Quadient used to be the UK-based Neopost, but was renamed in 2019 and is now based in Paris, though still with a UK office. It’s mid-range folder-inserter, the DS-700 iQ is probably closest to the BlueCrest Evolution in throughput terms, with up to 7,000 finished envelopes per hour. It can be configured with up to 11 feeders and can fold up to eight sheets, and is very expandable. Tower feeder folders are available in five variants with document accumulation speeds of up to 14,000 collations per hour. Jobs are set up with wizard helpers and up to 50 can be stored. Automated Insertion Management System (AIMS) monitors, verifies and reports on data integrity.
Contact Quadient 0845 880 0000 www.quadient.com
W+D (Winkler+Dünnebier)
The German mailing specialist makes several envelope inserting lines with different capabilities and performance. The BB700 S2 handles up to 16,000 envelopes per hour, with lots of servo assistance and automation. W+D says this line is particularly versatile, able to process personalised catalogues of different thicknesses, election documents, smooth photo paper, folded inserts or gimmicks, as well as standard letter formats.
Contact W+D +49 2631 840 www.w-d.de
USER REVIEW
“In the face of declining volumes and rising costs, this project was strategic for DocOne, aiming to streamline and maintain an efficient business model. After two years of deploying this equipment, the feedback is very positive: reduction in the number of machines, reduction in fixed costs and improvement in the quality of service for our customers” Gwenaël Lepareux, director general, DocOne, France
