Machines automate stamp splitting

Stephen Mayer produces machines that automate such tasks as splitting sheets of stamps into individual units, handling odd-shaped stamps, and affixing gummed stamps onto first day cover envelopes.

Stephen Mayer International is a Bristol-based design and automation engineering company that specialises in application-specific machines for the philatelic and food industries.

The company's standard product line includes a number of machines that automate such tasks as splitting sheets of stamps into individual units, handling odd-shaped stamps, and affixing gummed stamps onto first day cover envelopes.

Stephen Mayer customers include government post offices around the world, in countries such as the USA, Canada and Sweden.

The PAC-24 is a highly flexible system that has been designed and developed specifically for the United States Postal Service (USPS) in Kansas city.

It is the first machine of its kind that is capable of handling pressure-sensitive self-adhesive stamps and accommodates a wide variety of stamp sheets -including booklets - and an even wider range of target materials, such as first day cover envelopes and presentation sheets.

The machine automatically peels the stamps from their backing sheets and affixes them to the target material individually, in a line, or in a grid, depending on the customer's requirements.

The PAC-24 makes extensive use of electrical and pneumatic actuation technology, and Stephen Mayer chose to use Festo components throughout, principally on the basis that many of its earlier-generation systems employed Festo pneumatic equipment, and it had found Festo's customer support services to be highly responsive in both pre- and post-sales environments.

In use, the machine operator initially selects an appropriate platen to suit the size of the stamp sheet, and the machine then picks up each sheet of stamps using an array of 60 vacuum cups; individually controlled miniature solenoid valves switch the vacuum on and off to the piped cups.

The backing sheet is peeled off automatically and the stamps are then transported to the incoming envelopes or presentation sheet using X-Y tables driven by Festo electrical servo drives.

To ensure accurate and highly flexible placement, the stamps are individually set.

Any stamp from any position on the sheet can be directed to any position on the envelope.

A tamping cylinder then individually presses each placed stamp onto the envelope to affix it securely.

To maximise machine throughput there are two mirror-imaged stamp feeder stations on the PAC-24, arranged either side of the central indexing envelope feeder conveyor.

Finished envelopes are transferred via a camera checking station to a collating conveyor, and any unused stamps are placed on a recovery strip for stock control and auditing purposes.

In all, the PAC-24 is equipped with 10 Festo electrical servo drives, which are mainly used for the X-Y tables, the backing sheet removal co-ordination system, and positioning the tamping cylinder.

All of these drives, together with the system's four CPX valve terminals, are under Profibus co-ordination and control.

According to Dave Faulkner, Managing Director of Stephen Mayer International, "The PAC-24 makes best use of pneumatic and electrical drive technology to secure accurate and highly flexible stamp placement".

"The machine has a throughput of 2400 stamps per hour, which we believe is unprecedented in this market".

"By electing to use Festo components for its electrical and its pneumatic actuation requirements, we have gained a valuable single-source supply arrangement, and have also benefited from the integration skills provided by Festo's customer support services".

Creation of the PAC-24 was initiated by Stamp Fulfilment Services of USPS, with the intention of exploring a means by which USPS could improve its service to stamp collectors world-wide.

The criteria for the equipment was to affix either one or multiple stamps onto philatelic products created by USPS.

With this equipment, the accuracy of 'constant position' affixing will become standard, and lends itself to both single and multiple stamps affixed onto an envelope in the same position.

This accuracy will allow SFS to cancel stamps much more quickly and efficiently.

The cancelling machine can be set up with one process, in lieu of needing to alter the machine for affixing each specific stamp issue.

SFS plans to introduce the equipment to business alliances during meetings scheduled throughout 2007.

SFS intends hosting several of these meetings in order to share the advancements in equipment technology with customers - especially those handling first day covers.

As for the future, SFS Manager, Khalid Hussain will evaluate a business venue which will allow customers to submit large orders for affixing stamps onto their envelopes.

Hussain hopes to introduce this venue in mid- to late-2007.

The PAC-24 has been installed and beta tested at the USPS in Kansas City, and is now being rolled out to customers.

It is anticipated that further machine orders will materialise from other post offices around the world.

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