Direct mail processing has never been more competitive. Deadlines are tighter and margins have never been lower. To be competitive, you need the most productive inserting equipment available. Introducing the factory – remanufactured Pitney Bowes Mailstream Direct Ultra-High-Speed Inserter.


Ultra-High-Speed Inserting. 22,000 Cycles Per Hour
The PB Mailstream Direct is the most successful ultra-high-speed inserter ever produced. These machines, which originally cost close to a million dollars new, are brought into the PB factory, completely rebuilt, and modified for the
direct mail industry and released with the new name: PB Mailstream Direct. With a cycling speed of 22,000 pieces per hour, average output to the conveyor including read and print is 15,000 to 18,000 pieces per hour.

Built-in Quality Control Sample Diverts
Using the inserter’s operating system, and dedicated quality control diverters, the PB Mailstream Direct can divert based on true user-defined statistical samples or random samples. The QC process dedicates one of the divert bins for QC pieces. With an optional camera system, QC pieces can be identified within a barcode or OCR number, and then diverted.

4 Diverters to increase Integrity
Diverter 1 – missed envelope seals
Diverter 2 – mis-feed or double-feed pieces
Diverter 3 – dedicated to quality control samples
Diverter 4 – output camera divert

Electronic Double-Detection
Double feeds are becoming a common problem in the direct mail industry, especially with healthcare and
financial industry mailings. The PB Mailstream Direct electronic double–detect system is the most advanced system
in the industry, is completely automatic and does not involve any operator adjustments.

Parts and Service
The PB Mailstream Direct is the most successful ultra-high-speed inserter ever built with over 1,000 systems shipped worldwide. Pitney Bowes’ financial strength ensures a reliable inventory of parts and service for many years. Self-maintenance is recommended and a formal factory-service training program is available. Backup support and service from the factory can be relied on for years to come.

Work Cell Efficiency. Reduced Labor
The ultra-high-speed PB Mailstream Direct is designed to maximize production rates and reduce labor. Labor saving features include:
• Front loading envelope feeder
• Vertical conveyor
• Camera driven sorting and quality control system

Minimum Changeover Time
Unlike other ultra-high-speed inserting systems, the PB Mailstream Direct simplifies and reduces the time for job setup. Many of the procedures are completely electronic, with minimal operator involvement.

Flexibility of Feeding
The PB Mailstream Direct offers both rotary and friction feeders to handle more material quickly and accurately.

Friction Feeders
• Up to 26,000 inserts per hour
• Open-end leading inserts
• Z-folded inserts
• Porous material

Rotary Feeder
• Up to 26,000 inserts per hour
• High gloss single-panel
• High gloss half-fold
• High gloss multi-panel
• Chromate panel
• Prospectus-style booklet

Either Rotary or Friction Feeder
• Half-folded stitched thin booklet
• Perfume sample
• C-fold letter
• Bangtail BRE
• Single-panel non-glossy
• Half-folded letter

Ultra-High-Speed Read and Prints, Matching, and 100% Mailings
MCS and Pitney Bowes have been selling Ultra-High-Speed read and print systems for almost 10 years. No other companies have more integrity and experience than MCS and Pitney Bowes. The MCS Eagle can keep up with the Ultra-High-Speed of the PB Mailstream Direct with the same average production rates to the conveyor as a standard inserting job; 15,000 to 18,000 pieces per hour. MCS camera systems allow the APS DMTM to deliver:
• Match Jobs • 100% mailing jobs • Selective Inserting • Automated Quality Control


PB Mailstream Direct Remanufactured

Ultra-High-Speed Inserter

Standard Features


Cycling Speed

22,000 pieces per hour

Envelope Sizes

#10 and 6X9

High Capacity Front Loading Envelope Feeder

Holds up to 3,000 envelopes

3 Feeders

1 Rotary, 2 Friction


4 Diverters

Inkjet/Camera Table

42" vacuum

Double Detection

Electronic and automatic. No operator adjustment. Detects both doubles and absence of material.

Quality Control

User-defined statistical and random. Optional barcode-embedded.

High Capacity Vertical Conveyor

10 feet long. Stacks envelopes vertically.




6 Feeders

2 Rotary, 4 Friction

MCS MicroVision Camera in Feeder

Reads 1 sq. in. area either 2D barcode or OCR. Camera controls:

Read and print, matching, selective pocket, sequential checking and tray breaks.

MCS MicroVision Camera in QC Area

Reads 1 sq. in. area either 2D barcode or OCR. Camera controls:

QC checks and tray breaks, diverts into dedicated misread or QC bin.

MCS Area Camera in QC Area

Reads 3"X4" area either 2D barcode or OCR. Camera controls: QC checks and tray breaks, diverts into dedicated misread or QC bin.

MCS Line Scan Camera On Inkjet/Camera Table

Reads 6"X9" area, can be used for QC, 2D barcodes, IMB, verify stamps, logos, and print.

Sort Marking System

Tray breaks are marked on envelopes with visible or UV invisible ink. Feature requires MCS camera.

Sort Offset System

Tray breaks are physically offset on vertical conveyor, needs feeder or QC camera.





PB Mailstream Direct - Download Brochure