While any automated mail sorting machine is superior to manual processing, the difference between entry-level and top-rated solutions is significant. Find the best machines for sorting and processing return mail from top manufacturers.
It’s Time to Move on From Manual Processing
Processing mail by hand is time-consuming and lacks much-needed capabilities like imaging, tracking and reporting. If your parcel sorting or return mail processing volume fluctuates unexpectedly, it can create backlogs and bottlenecks that slow your other workflows.
Modern equipment is superior to hand processing because it can process thousands of pieces of mail an hour. It frees up staff for more important tasks and significantly increases productivity. Automation optimizes labor, reducing your spending on hourly workers and overtime. Even though the upfront cost can be significant, it is a cost-effective and worthwhile choice.
If you are going to invest in an automated mail sorting machine, you shouldn’t settle for less than the best. Innovative products push the boundaries of mail processing, effectively future-proofing your system.
How We Chose the Best Mail Processing Machines
Your mailing environment demands a reliable, high-performance system that meets your needs and budget. A machine is only “revolutionary” if it achieves high throughput, user-friendly operation, high-speed processing with cutting-edge software and hardware. A small form factor and modular configuration are bonuses.
The following five automation system providers meet or exceed these standards. They also offer superior sales and technical support. The mail machines all serve various industries and have versatile product lines. Many provide custom solutions and optional add-ons for customer-centric experiences.
What Are the Best Machines for Sorting and Processing Return Mail?
These five industry-leading companies offer the best automated mail sorting machines.
1. Oasis from Tritek
Tritek has nearly half a century of experience and dozens of patents. Its professional team will work with you personally to design, develop and manufacture mail sorting equipment that meets your needs. All products are built to order and include a one-year manufacturer’s warranty. These low-maintenance systems are easily serviced and do not require an on-site technician.
The Oasis from Tritek is an automatic, high-speed sorting machine. It handles up to 10,000 mail pieces an hour for streamlined return mail processing. It will quickly handle letters or flats, regardless of their orientation. While it can interface with all the company’s software — including Return Mail software — it also integrates with third-party applications.
This is the best machine for sorting and processing return mail because it goes beyond the basics. It has complete imaging, scanning and digital mail delivery features. It can even open mail and retrieve documents if needed. A feeder, duplex camera imager and collection bins fit in its small form factor, enabling large-scale imaging at 300 dots per inch.
2. Simex Flexi from BOWE SYSTEC
BOWE SYSTEC is one of BOWE GROUP’s three specialized divisions. It has designed mail sorting and document processing technology for over 75 years. Everything is European-made, but it can offer 24/7 local sales and service support because it has dozens of subsidiaries in North America. For post-sales support, you can request a custom service package.
The Simex Flexi is a mixed-mail sorter that places inbound mail into vertical stacks or tubs on either side. It uses barcode recognition (BCR) and OCR technology. The fully integrated BOWE IQ sorting software can automate returns handling with a custom sort scheme. Depending on your needs, you can also tailor the configuration for nine to 192 sort bins.
3. Sure Sort X® from OPEX Corporation
Family-owned OPEX Corporation developed Sure Sort X® based on customer feedback on the original model. It also drew on its 50 years of experience, 345 issued patents and over 1,100 successful installations for insights. The result was a state-of-the-art automated sorting system handling almost 100% of customer-sortable products.
Compared to the original Sure Sort® machine, it can process items that are around 60% smaller, 20% larger and four times as heavy. Its applications include returns processing, parcel sorting, inventory management and in-store fulfillment. It works in temperatures ranging from 34 degrees Fahrenheit to 90 degrees Fahrenheit.
OPEX Corporation will be with you from start to finish, offering everything from solution architecture to hands-on operator training. Post-sales support includes 24/7 technical support. Its team of 550 trained service technicians averages nearly 10 years of experience. Since they are locally based, they can respond within two hours.
4. BlueCrest Elevate® from BlueCrest
Elevate® from BlueCrest is a flexible, high-speed mail processing machine. Despite its compact size, this machine is crammed with cutting-edge technologies like duplicate mail piece detection and piece-level tracking. Thanks to its unique two-tier configuration, it has a small footprint for its throughput.
This machine’s advanced functionality allows it to efficiently process many types of mail at speeds of up to 18,000 items per hour. It ensures sorting accuracy with BCR technology that covers height, thickness and duplicate detection. The inline opener can open select envelopes based on sort schemes. You can also add magnetic ink profile recognition to detect if marks are present.
5. Dispatcher MX from ID Parcel & Mail Solutions
As a smaller company, ID Parcel & Mail Solutions is happy to take on the projects that larger automation system providers may not consider worth their time. The provider’s overhead costs are relatively low and its operations are localized, so it can offer high-quality solutions at an affordable price.
Its Dispatch MX series combines automatic and manual feeding stations for flat, letter and mixed mail up to 1 3/8 inches thick. The 12-foot field-of-view camera allows for precise mailing alignment, ensuring items are sorted accordingly. You can configure it with OCR or BCR technology. You can also tailor the number of sorting outlets and the type of turning modules.
Comparison of the Automated Mail Systems
Machine size, throughput and turnaround time are the most critical at-a-glance variables when deciding on mail sortation solutions. How fast you get your hardware and how quickly it processes mail impact your productivity and return on investment (ROI).
| Mail Sorting Machine | Machine Size | Throughput | Turnaround Time |
| Tritek Oasis | Modular design and configuration | Up to 10,000 mail pieces an hour | Fast turnaround |
| Simex Flexi sorter | Modular design and configuration | Up to 40,000 mail pieces an hour | Fast turnaround |
| Sure Sort X | Starts at 16.5 feet long and 14.6 feet wide | Up to 2,100 mail items an hour | Average turnaround |
| BlueCrest Elevate | Starts at 14.3 feet long and 6.2 feet wide | Up to 18,000 #10 envelopes per hour | Average turnaround |
| Dispatcher MX | Modular design and configuration | Up to 10,000 mail pieces an hour | Average turnaround |
Beyond these factors, you should also consider pricing. Remember, the upfront cost is only a portion of the ROI calculation. Companies like Tritek offer competitive warranties, flexible payment options and rentals to fit your budget and income cycle.
Which System Provider Should You Choose?
Now that you know these are the best machines for sorting and processing return mail, you can decide which works best for you. Consider pricing, applications, optional features and post-sales support. Companies with proprietary software and time-tested technologies will deliver practical, long-lasting solutions. Consider reaching out for more specific technical specifications.
