Apparatus for inserting documents into envelopes and associated method

An apparatus for inserting documents into envelopes, comprising:

• a document insert station;
• a document conveyor that conveys documents horizontally to be inserted within envelopes to the document insert station, each envelope having an envelope opening and a flap to close the opening and defining a hinge line at the intersection of the flap and envelope opening;
• an envelope feeder that feeds envelopes upside down with the hinge line facing downward and into the document insert station and at an angle away from the document conveyor and on the hinge line with the flap oriented upward from the hinge line away from the document conveyor;
• an insert plate having a beveled edge and positioned at the document insert station that receives a document conveyed from the document conveyor and having orifices though which air is blown onto the envelope to open the envelope, wherein the insert plate is configured to engage the flap of the envelope at the beveled edge of the insert plate and force the flap to extend under the insert plate at its beveled edge and retain the flap open, and wherein air is blown through the orifices to open the envelope;
• an envelope sealer positioned after the document insert station that seals the flap over the envelope opening;
• and
• a lay down mechanism positioned after the envelope sealer and configured to lay down the envelope into a horizontal position.