Mailing Machinery Portfolio
Explore a range of my mechanical design projects tailored for the mailing industry. This portfolio highlights my role in modernizing legacy systems and developing new equipment to improve speed, reliability, and customization in high-volume mailing operations. From redesigning folder systems to integrating smart feeders and automation enhancements, each project reflects a practical, solutions-oriented approach to machine building. These machines were engineered with real-world performance in mind—balancing mechanical simplicity with functional precision to meet the evolving needs of a shrinking but demanding industry.
The SFM100C is a robust two-plate paper folding machine built for high-volume self-mailer production. It supports multiple fold types and integrates essential features like variable speed control and glue application, making it a practical and reliable solution for mailing operations.
Self-Mailer Folding Machine – SFM100C
The VS100 is a standalone vertical stacker engineered for compatibility with a range of pharmaceutical folding machines already in use across the industry. Designed for high-volume environments, it provides a compact and efficient stacking solution that helps streamline downstream handling while maximizing floor space efficiency.
VS100 Vertical Stacker
The Vacuum and Stacker Conveyors were developed to support high-speed handling and organization of materials during variable data and barcode printing. These conveyors—though originally built as prototypes—are designed with production-level durability and performance in mind. They enhance precision and workflow efficiency while adapting easily to a variety of print applications and system configurations.
Vacuum & Stacker Conveyors
Developed as the foundation for a next-generation smart feeder system, this 4-plate folder module showcases my design contribution to automated mailing solutions. While I left the company before the full system was completed, the folder module itself was finalized and sold to a separate firm founded by former GBR engineers, who used it to build their own system—extending the design’s legacy in the mailing industry.
4-Plate Folder Module
The C1000-6S is a custom-engineered feeder and auto-loader assembly designed to streamline high-volume mailing workflows. Built to handle larger sheet sizes, this system integrates smoothly with existing mailing inserters, ensuring reliable synchronization, accurate feeding, and efficient downstream processing.
