The CardMailer came about from a specific card match and attach enquiry from the APS Group a few years ago.

KAS managing director Stephen Hampstead said: “Initially we quoted a KAS Enfolder and Mailmaster envelope inserter with a third-party match and attach unit. When it became clear that one of the cards to be attached was too large, at 106x148mm, for the third-party machine, we looked into and eventually designed our own match and attach system with hot-melt gluing.

“The order came in and we started manufacturing about a week before the first Covid lockdown was announced, so it was fortunate that we were doing virtually everything in-house and not travelling to suppliers around the country or world. The machine was delivered a few months later and a second machine was ordered in early 2022, this time with in-line envelope weighing.”

Hampstead said KAS has since sold another of these machines – now called the CardMailer and a permanent addition to the KAS core standard portfolio with immediate effect – to a client in Ireland in 2023 and is talking to a number of other interested parties in the UK and globally.

Hampstead said one of the device’s main features is its flexible and modular design, with optional in-line envelope inserting, carrier printing, camera matching, envelope weighing and addressing.

Outlining specifications, he added: “Firstly, there are two options for the card carrier, which can either be pre-printed or printed on-line. When pre-printed, it’s fed as the primary document, which can be an A4 sheet, or a document with the same dimensions as the envelope, such as an A5 postcard.

“Alternatively, the carrier can be printed on-line, with a floor standing office printer instead of the primary feeder. The card, as the primary document, is fed and read and this data is sent to the customer’s print server to print the personalised carrier. The CardMailer can be supplied with both options.

“In either case, the carrier can be folded before or after the card has been attached, depending on the application. The card is fed from a top-load, bottom-feed shuttle feeder, and attached to the carrier with hot melt glue.

“More than one card can be attached to the carrier. When the carrier and card are attached, codes on both are read by cameras, and this data can be used for matching and/or recording to a file for reporting. If they don’t match, the item is diverted before going any further.

“A KAS Mailmaster envelope inserter can be placed in line to receive the carrier and attached card. Additional multiple enclosures can be added, from a single sheet of 80gsm, stapled sets, pre-folded items, reply envelopes, and booklets up to 7mm thick, fed from automatic feeders. The completed pack is then inserted into the envelope and sealed.”

Pricing was not disclosed as KAS said the CardMailer is bespoke with different configurations.