Mailer machine for multiple, different mailer configurations and method of use

A method of packaging a product in a mailer using a mailer packaging apparatus, wherein the mailer packaging apparatus comprises a handling station having a robot, a mailer supply station having a plurality of magazines for holding mailers, and a product supply station having one or more product receptacles, the method comprising:

• moving a first magazine of the plurality of magazines adjacent to the robot and a second magazine away from the robot, wherein the first magazine is configured to hold a plurality of first mailers and the second magazine is configured to hold a plurality of second mailers, and wherein the plurality of magazines are movable with respect to the robot;
• and
• moving the robot to pick the mailer from the first magazine adjacent to the robot;
• positioning the product within a receptacle of the product supply station by moving a first wall or a second wall with respect to each other to locate the product in the receptacle before packaging in the mailer;
• and
• supplying the product from the product supply station to an opening of the mailer.

A mailer packaging apparatus comprising:

• a handling station having a robot;
• a mailer supply station having a plurality of magazines for holding mailers, the plurality of magazines having at least a first magazine configured to hold a plurality of first mailers and a second magazine configured to hold a plurality of second mailers, and wherein the plurality of magazines are movable with respect to the robot;
• and
• a mailer closing station configured to close the mailers, the mailer closing station comprising:
• an external folding member configured to be positioned on a first outer surface or a lip of a mailer;
• an internal folding member configured to be positioned on an internal surface or a second outer surface of the mailer;
• a closing actuator operatively coupled to the external folding member;
• wherein the robot is configured to pick the mailer from one of the plurality of magazines;
• wherein a product is supplied to the mailer for packaging;
• and
• wherein the external folding member of the mailer closing station is configured to engage the first outer surface of the mailer or the lip to fold the lip of the mailer around the internal folding member for operatively coupling the lip to the second outer surface of the mailer to close an opening of the mailer after the product is supplied to the mailer.

A method of packaging a product in a mailer using a mailer packaging apparatus, wherein the mailer packaging apparatus comprises a handling station having a robot, a mailer supply station having a plurality of magazines for holding mailers, and a mailer closing station for closing the mailers, the method comprising:

• moving a first magazine of the plurality of magazines adjacent to the robot and a second magazine away from the robot, wherein the first magazine is configured to hold a plurality of first mailers and the second magazine is configured to hold a plurality of second mailers, and wherein the plurality of magazines are movable with respect to the robot;
• and
• moving the robot to pick the mailer from the first magazine adjacent to the robot;
• supplying the product to the mailer for packaging;
• closing the mailer with the product in the mailer closing station having an internal folding member, an external folding member, and a closing actuator operatively coupled to the external folding member, wherein the external folding member engages a first outer surface of the mailer or a lip to fold the lip of the mailer around the internal folding member positioned on an internal surface or a second outer surface of the mailer for operatively coupling the lip to the second outer surface of the mailer to close an opening of the mailer after the product is supplied into the mailer.

A mailer packaging apparatus comprising:

• a handling station having a robot;
• a mailer supply station having a plurality of magazines for holding mailers, the plurality of magazines having at least a first magazine configured to hold a plurality of first mailers and a second magazine configured to hold a plurality of second mailers, and wherein the plurality of magazines are movable with respect to the robot;
• a packaging station configured to receive the mailers and open the mailers;
• a product supply station configured to supply products to the mailers;
• and
• a controller operatively coupled to the handling station and the mailer supply station and configured to operate the handling station and the mailer supply station;
• wherein the controller receives an indication of a product from a product system being received in the mailer packaging apparatus;
• wherein the controller determines a mailer for the product being received from one of the plurality of magazines holding the mailers;
• and
• wherein in response to determining the mailer, the controller moves the first magazine of the plurality of magazines adjacent to the robot and the second magazine away from the robot;
• wherein in response to determining the mailer, the controller activates the robot to pick the mailer for the product from the plurality of magazines;
• wherein the packaging station receives the mailer from the robot and opens the mailer;
• and
• wherein the mailer receives the product from the product supply station.

A method of packaging a product in a mailer using a mailer packaging apparatus, wherein the mailer packaging apparatus comprises a handling station having a robot, a mailer supply station having a plurality of magazines for holding mailers, a packaging station for receiving the mailers and opening the mailers, a product supply station for supplying products to the mailers, and a controller operatively coupled to the handling station and the mailer supply station for operating the handling station and the mailer supply station, the method comprising:

• receiving, via the controller, an indication of the product from a product system being received in the mailer packaging apparatus;
• determining, via the controller, the mailer for the product being received from one of the plurality of magazines holding the mailers;
• in response to determining the mailer, moving, via the controller, a first magazine of the plurality of magazines adjacent to the robot and a second magazine away from the robot, wherein the first magazine is configured to hold a plurality of first mailers and the second magazine is configured to hold a plurality of second mailers, and wherein the plurality of magazines are movable with respect to the robot;
• in response to determining the mailer, activating, via the controller, the robot to pick the mailer for the product from the first magazine of plurality of magazines;
• opening the mailer in the packaging station after receiving the mailer from the robot;
• and
• delivering the product to the mailer from the product supply station.