First Field Deployment of OttoMATE Trayer Cobot at Forge

Danbury, CT — January 16, 2025— BlueCrest is a leader in mail production and postal automation. They have finished the first field deployment of their OttoMATE® Trayer Cobot. This deployment took place at Forge, a leader in digital, print, and mail fulfillment. This deployment showcases BlueCrest’s commitment to delivering cutting-edge solutions that address real-world challenges in today’s competitive business environment.

Tackling Industry Challenges with Automation Technology

Forge is a company that helps clients create unique communications. They use digital, print, and mailing technology. However, they have faced challenges with labor. These include staffing issues and safety concerns. These problems keep valuable workers from doing their jobs. 

Understanding that employee well-being directly impacts productivity, Forge sought a solution that would reduce labor challenges, mitigate workplace injuries, and improve overall efficiency.

If you show your employees that you’re willing to invest in them, they’ll invest back into you. But you do have to show them that you are investing in their well-being.

Jason Fonner

VP Print Operations, Forge

The OttoMATE Trayer Cobot has been strategically integrated onto the BlueCrest Epic high-speed inserter, presenting a cutting-edge solution for the efficient handling of finished mail pieces. This innovative collaboration between the OttoMATE Trayer Cobot and the BlueCrest Epic inserter represents a significant advancement in automation technology within the mailing industry.

The OttoMATE Trayer is a robotic arm cobot. Designed with advanced robotics and artificial intelligence, it is capable of seamlessly interacting with the high-speed inserter to automate the process of traying mail pieces. This integration not only enhances operational efficiency but also reduces the potential for human error. This, in turn, ensures that each mail piece is accurately and securely placed into trays for distribution.

The BlueCrest Epic inserter is renowned for its high-speed capabilities. And it is well-known for the rapid and accurate processing of large volumes of mail. By incorporating the OttoMATE Trayer Cobot, the system can now handle the final stages of mail processing with greater speed and precision.

The cobot can work with human operators. It takes on repetitive and hard tasks. This allows staff to focus on more complex and valuable activities.

This smart solution is very helpful in an industry that needs fast turnaround times and high accuracy. The OttoMATE Trayer Cobot makes the workflow smoother and boosts the productivity of mailing operations. As a result, businesses can expect better efficiency, lower labor costs, and improved service for their customers.

The OttoMATE Trayer Cobot and the BlueCrest Epic high-speed inserter work together to improve mailing technology. This new solution transforms how we process mail. It makes everything faster, more efficient, and more reliable than before.

Boost Productivity with Groundbreaking Technology for Enhanced Productivity

The OttoMATE Trayer combines innovative collaborative robot technology with ease of use to revolutionize tray-filling operations. 

By automating labor-intensive tasks, the Cobot boosts productivity and reduces physical strain on employees. Its capabilities include:

• Filling more trays faster than the average operator while maintaining operations 24/7.
• Keep inserters operating at peak performance without adding labor costs.
• Providing a user-friendly interface that operators quickly adapted.

“The operators were initially unfamiliar with the technology, but that quickly changed,” said a member of Forge’s management team. “It wasn’t long before they grew comfortable operating the Cobot as though it were any other piece of equipment on the floor.”

Results That Speak Volumes

The OttoMATE Trayer deployment has yielded remarkable results. The Epic inserter equipped with the OttoMATE Trayer is the best-running Epic at their Florida site.

Employees are now vying for the opportunity to work with the innovative machine and robotic system. Beyond merely alleviating labor shortages, the Cobot has significantly enhanced Forge’s reputation, positioning the company as a progressive and technology-driven organization. This advancement not only showcases Forge's commitment to innovation but also attracts potential clients and partners who value modern solutions.

“The Cobot has been running flawlessly. We can’t get rid of it now; our operators are all vying for a chance to use that inserter,” a Forge team member remarked.

In the future, Forge is actively planning to leverage the capabilities of USPS Intelligent Traying to enhance and streamline their operational processes even further. By implementing this innovative system, they aim to utilize OttoMATE, a sophisticated tool designed to optimize the filling of mail trays to their maximum capacity. This strategic approach will not only improve efficiency but also significantly reduce the total number of trays needed for their mailing operations. Ultimately, this will lead to cost savings and a more sustainable approach to mail handling.