System and method for high-speed insertion of envelopes

A system for inserting contents into envelopes comprising:

• an envelope hopper and an envelope pusher assembly that drives envelopes from a bottom of the hopper in a downstream direction;
• an envelope transport that grasps envelopes from the pusher assembly and forwards the envelopes in the downstream direction to a stationary position at a contents stuffing station at which the envelopes each receive respective contents thereinto, the transport operating at a fixed timing with respect to the pusher assembly;
• a front hopper guide that engages a leading downstream edge of the envelopes, the front hopper guide being constructed and arranged to adjustably move in an upstream-to-downstream direction so as to accommodate envelopes having differing upstream-to-downstream widths;
• and
• wherein the stuffing station includes sliding pusher fingers adapted to move from a withdrawn position to drive contents from a raceway into each of the envelopes, each of the pusher fingers having a magnet disposed therein and a the stuffing station further including a magnetic pusher plate against which the pusher fingers are biased by each magnet, respectively.