234 hours.

That's how much time a mid-volume mail shop spends every year printing, collating, walking, and recalling tray tags and pallet placards. Super conservative. Most shops that count reruns honestly are closer to 560 hours.

What would your floor do with 234 more hours of productive time? Run more jobs. Reduce overtime. Cross-train staff. Take on the work your competitor can't handle because they're still printing paperwork.

See the Business Case See How It Works

Where 234 hours goes — every year

Print tray tags (laser, collate by tray order) 78 hrs
33%
Print pallet placards (laser, sort by pallet) 47 hrs
20%
Deliver paperwork to production stations 39 hrs
17%
Rerun recall — find and destroy old tags 39 hrs
17%
"Where's that job?" — status checks across staff 20 hrs
9%
Reprint requests — pull processor off current job 11 hrs
5%
Based on 15 jobs/week, 1.25 paperwork cycles/job, 50 weeks/year.
Shops averaging 2-3 reruns per job: 560+ hours — more than double.

The math — at 15 jobs per week

Every presort run generates paperwork: tray tags, pallet placards, production reports. Printed on a laser, collated by hand, walked to the floor.

Every job generates at least one round of paperwork. About 25% need a rerun — thickness correction, client changes, spec updates — which means recalling old paperwork from the floor and replacing all of it.

At 15 jobs per week, using a conservative 15 minutes per paperwork cycle, that's nearly 5 hours per week spent on paperwork alone. A number most processors would call generous.

What 234 hours buys you: That's 6 additional full work weeks per year. Enough to run more jobs at the same staffing level — or give your best people time back for quality, training, and the work that actually grows the business.

234
hours per year recovered
Time your processors, supervisors, and operators spend on paperwork that doesn't move a single piece of mail. FloorPulse eliminates every minute of it.
Traditional workflow FloorPulse workflow Presort run completes Print tray tagsDesktop app, laser printer Print pallet placardsCollate by pallet order Walk paper to floorDistribute to stations Production runsSort through tag stacks Rerun required Recall old paperworkFind and destroy old tags Repeat per rerun ~15 min per cycle234 hrs / 29 days per year* Error risksWrong tag on wrong trayOld tags used after rerunDouble-pulled placardsPre-tagging surprises *15 jobs/wk, 1.25 cycles/job, 50 wks Presort run completes Mail.dat drops in hotfolderAuto-detected, validated Supervisor creates jobOne click, floor is ready Operator scans piece IMbKeyboard wedge or camera Tray tag prints on demandZebra at the workstation Pallet placard auto-printsLast child tray triggers it Rerun required New mail.dat replaces oldFloor has current data instantly Resume scanning 0 min paperwork234 hrs / 29 days recovered* Built-in protectionsNo tag until tray is scannedNo old tags to recallDuplicate scan detectionMismatch flagged instantly

How FloorPulse works

1

Drop a ZIP

FloorPulse consumes the mail.dat file directly from presort software output. Drop the ZIP into a watched folder. The job is live in seconds. No manual data entry. No file conversion.

2

Scan and print

Operators scan the piece or tray barcode. FloorPulse matches it against the mail.dat, resolves the container, and prints the tag on demand. No preprinted tag stacks. No sorting through paper.

3

Pallets complete themselves

When all trays in a pallet are scanned, the placard generates automatically. Real-time progress visible to every workstation and supervisor on the floor.

4

Reprocess without risk

Job reprocessed? Drop the new mail.dat. FloorPulse detects the duplicate, verifies no production activity, and replaces the old data instantly. No old paperwork to recall — it was never printed.

What this eliminates

Preprinted tag generation

No more printing hundreds of tray tags per job, collating them by tray order, and walking them to the floor.

Paperwork recall

When a job is reprocessed, there's no old paperwork on the floor to find and destroy. Tags are printed on demand — no scan, no tag.

Pre-tagging errors

Operators can't place tags in trays in advance if the tags don't exist yet. The entire category of pre-tagging problems disappears.

Mismatch detection

A barcode scan that doesn't match the active mail.dat is a red flag — caught before a single piece prints wrong, not at postal acceptance.

Processor interruptions

Reprints are self-service from any device on the floor. Floor staff don't pull the processor off their current job for a single tray tag.

Static cling and double-pulls

One scan, one placard, one pallet. No warm laser paper sticking together. No missing placards discovered at the dock.

Everything in the box

One license. One install. Every feature below — no add-ons, no modules to unlock, no per-feature pricing.

Production Workflow

  • Automatic mail.dat import — drop a ZIP from any presort software, job is live in seconds
  • Scan-to-print tray tagging — scan a piece barcode, tray tag prints instantly at the workstation
  • Automatic pallet placard generation — last child tray triggers the placard, no manual step
  • Duplicate barcode resolution — smart matching based on sort position, handles seed barcodes across trays
  • Forward and reverse sort direction — per-workstation, matches equipment physical output
  • Multi-station production — multiple workstations on the same job, real-time collision detection
  • Instant reprint — damaged or lost tags reprinted with one click from any device
  • Job reprocessing — new mail.dat replaces old data instantly, no paperwork to recall
  • Configurable mailer zones — tray tag printer line, mailer's area, and pallet detail columns customizable per site
  • Equipment Station — scan piece IMb at any pre-floor equipment (digital press, folder, cutter, inserter) to verify job, segment, and destination in real time. Tracks presort sequence numbers, replacing manual paper logs
  • Equipment Monitor — supervisor view of all equipment activity with tray inference engine. Calculates completion from sparse scan samples — pieces, trays, pallets done vs total, run speed, estimated remaining time. Reprint mode separates re-run scans from production data

Supervisor & Visibility

  • Real-time supervisor dashboard — job progress, tray/pallet completion, segment tracking, all live
  • Active workstation monitoring — see who's scanning what, from any screen
  • Pallet drill-down — filter by facility type, destination, locale key, ship date
  • Job lifecycle management — create, go live, archive, with full history
  • WebSocket push updates — dashboards update in real time without refreshing

Print & Hardware

  • Zebra ZPL thermal printing — direct TCP to any Zebra printer on the network
  • Microcom LDS printing — native Microcom 438/478 support
  • Laser printer placards — pallet placards via CUPS/IPP to any network laser
  • USPS-compliant tray tags — L-3216A layout, ISS Code 128, correct barcode dimensions
  • USPS-compliant pallet placards — DMM 204 Exhibit 3.4.3, IMcb barcode
  • Bluetooth and USB barcode scanners — keyboard wedge input, works with any IMb capable HID scanner
  • Camera barcode scanning — phone or tablet camera as a fallback scanner
  • Network printer discovery — automatic scan finds printers on your LAN

Quality & Operations

  • QC Inspector — scan any barcode to trace its job, tray, pallet, and print history
  • Import log with full history — every import tracked: completed, replaced, rejected, failed
  • Data editor — modify imported data within FloorPulse for anonymization or correction without affecting original mail.dat files
  • Performance monitoring — scan-to-print timing, health alerts, disk/memory dashboards
  • Bilingual help system — in-app help in English and Spanish on every page
  • Configurable data retention — automatic purge of piece-level data on your schedule
  • Read-only database access — query your own production data for custom reports
  • mail.dat v23, v24, v25, v26 — all current USPS DTAC/IDEAlliance schema versions supported

Deployment

Ships as a Docker container — runs on any machine with Docker installed. Windows, Linux, or Mac. The database, runtime, and application are all packaged together. Security patches apply with a single command. In-app update notifications tell the supervisor when a new version is available. No dedicated IT staff required to operate.

The cost you've stopped counting

These aren't failures. They're infrastructure gaps that every mail shop has absorbed as normal. They're not normal — they're expensive.

70
days per year

The Rerun Cascade

A typical job reruns 2-3 times — thickness corrections, list revisions, insert changes. Each rerun triggers a full paperwork cycle: reprint tags, reprint placards, deliver to the floor, find and destroy the old versions. At 15 jobs a week and 3 runs per job, that's 70 eight-hour days a year spent on paper that doesn't move a single piece of mail. FloorPulse eliminates the cascade — new mail.dat replaces the old one instantly. No paper to recall because it was never printed.

The 29-day figure on this page assumes 1.25 paperwork cycles per job — essentially one run plus the occasional rerun. Most processors will tell you 2-3 runs per job is closer to reality. The difference between 29 and 70 days is how honest you are about how often jobs rerun.

1+ hr
per day, across staff

The Status Tax

Where's that job right now? The supervisor walks the floor. The ops manager calls on the radio. Shipping asks if that destination is ready. Customer service calls downstairs because their client wants an update. Five or six people, 15 minutes each, every day — chasing a question that should have a permanent answer on every screen in the building. The expensive part isn't the time. It's the decisions made on stale information.

2
machines, same data

Duplicate Production

Two inkjets running the same job. Operator at station 3 scans a piece — the tray tag already printed at station 7. Without real-time visibility, you find out at the dock. Or you don't. FloorPulse flags it at the scan — before time, materials, and postage are wasted. Every workstation on a job sees every other workstation's progress in real time.

∞
every piece, every scan

Chain of Custody

Every client walkthrough looks the same — inserters, conveyors, pallets, clean and organized. What separates your shop? Show them the chain. Every piece barcode scanned, every tray tag printed, every pallet placard generated — timestamped, traceable, and queryable from any device on the floor. Scan any piece and see exactly where it is, which tray it's in, which pallet it belongs to, and when it was processed. Not a slide deck. Not a promise. Pull up any screen on the floor and demonstrate it live, with their job, while they're standing there. Not because regulation requires it. Because your operation is that precise.

Built for the production floor

On-premises
Runs on a single machine on your local network — Windows, Linux, or Mac. No cloud. No external dependencies. Production doesn't stop if the internet goes down.
Browser-based
Every workstation, supervisor station, and QC device accesses FloorPulse through a web browser. Tablets, phones, desktops — no app to install.
Direct print
Drives thermal tag printers, Zebra ZPL, Microcom LDS, and standard laser printers directly over the network. No print server middleware.
mail.dat native
Parses mail.dat files directly from any presort software — BCC, Anchor, Accuzip, and others. Multiple USPS DTAC/IDEAlliance schema versions supported.
Modular
Core platform supports additional application modules. Commingle and co-palletization routing are on the product roadmap.

Simple deployment

Ships as a Docker container — runs on any machine with Docker installed. Windows, Linux, or Mac. The database, runtime, and application are all packaged together. Security patches apply with a single command.

No database server to provision. No IT project. No dedicated hardware required — it runs on whatever you have. Connect to the network, open a browser. Designed to go live in an afternoon, not months.

See it in action

Workstation Dashboard

The operator's scan-to-print interface. Scan a piece barcode, print the tray tag — one step.

Supervisor Dashboard

Real-time production visibility across all jobs, workstations, and segments on the floor.

Mobile Scan to Print

Scan a piece barcode with an iPhone camera and print the tray tag instantly. No app — just a browser.

QC Inspector demo ▶

QC Inspector

Look up any piece, tray, or pallet by barcode. Reprint tags, trace missing mail pieces, verify production.

Pricing & Registration

4,000 facilities. Nearly all of them manual.

There are approximately 4,000 Mail Service Provider facilities in the United States that process mail using presort software and mail.dat files.

A small number of large-volume mailers have built internal automation — they could afford to hire a programmer. The other facilities have not, because no product has existed at a price point and implementation complexity that made sense for their operation.

FloorPulse is purpose-built for this gap: affordable software that runs on any machine on your network — Windows, Linux, or Mac — and requires no specialized IT staff to operate.

~4,000 MSP facilities in the U.S.
0 affordable production visibility products available to them — until now

See it run

FloorPulse is built, tested with production-scale data, and ready for its first facility deployments. If you're a Mail Service Provider still processing tray tags in batch, or an investor interested in the mailing industry's automation gap, let's talk.