Shiny Mail Barcode Application via Non-Shiny Label Mediator
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Solution Overview
Problem
Shiny mailpieces pose a challenge in mail processing due to their non-porous surfaces, which cause applied barcodes and ID Tags to smudge or become unreadable, leading to manual sorting and increased costs, as existing systems struggle to efficiently handle such items.
Innovation Solution
The implementation of a Reject Encoding Machine (REM) with an on-board OCR engine that over-labels shiny mailpieces with non-shiny labels, allowing for the application of a new barcode and ID Tag in the POSTNET and ID Tag clear zones, enabling automatic sorting by creating a resolvable image and using advanced OCR algorithms to resolve addresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If barcodes and ID Tags are applied directly to shiny mailpieces, then the processing speed is maintained, but the barcodes become unreadable due to smudging
Solution Approach 1:
A label is introduced as an intermediary carrier between the barcode application system and the shiny mailpiece surface. The label provides a non-shiny, ink-receptive surface that allows barcodes and ID Tags to be applied reliably, while the label itself is designed to adhere to the shiny mailpiece surface. This mediator resolves the contradiction by enabling reliable barcode application without direct contact with the problematic shiny surface.
Solution Approach 2:
The solution changes the surface parameter of the mailpiece interaction point by introducing a label with different surface properties (non-shiny, porous) compared to the original shiny mailpiece surface. This parameter change enables ink absorption and barcode formation while maintaining compatibility with the shiny underlying surface.
2Reliability
If shiny mailpieces are sent for manual sorting, then barcode readability is ensured, but processing time and costs increase
Solution Approach 1:
The system performs preliminary identification of shiny mailpieces using optical detection before the barcode application process. By detecting the shiny surface property in advance, the system can proactively apply labels to these pieces, preventing subsequent barcode smudging and avoiding manual sorting requirements. This preliminary action eliminates the need for time-consuming manual intervention.
3Reliability
If a label is applied to shiny mailpieces before barcode application, then barcode readability is improved, but device complexity increases
Solution Approach 1:
The label application system is designed to handle multiple functions: identifying shiny mailpieces, applying labels, and preparing pieces for barcode application. By making the label application device multi-functional, the system avoids adding separate dedicated equipment for each function, thereby limiting the increase in overall device complexity while achieving reliable barcode application on shiny surfaces.
Data Source
AI summary
Methods, apparatus, software and systems are disclosed for improved processing of mailpieces in order to reduce expensive manual steps. Shiny mail, i.e., mailpieces having glossy surfaces that sometimes interfere with printing of barcodes and or ID Tags may lead to rejects. In some embodiments, shiny mailpieces are identified, and at least one new (non-shiny) label is over-labeled in the POSTNET clear zone (108), the ID Tag zone (202), or both. In one embodiment, a specially-configured Reject Encoding Machine (REM) (1142) is employed to label or over-label a POSTNET clear zone (1110), resolve the destination address (1112) if possible, and print the barcode (1114) in a single operation. Thereafter, the mailpiece may be transferred from the REM into a downstream DBCS (1144), thereby re-introducing the mailpiece into the automated mail stream rather than being relegated to a manual stream.