Two minutes on what FloorPulse does on a live production floor.

Where 234–560 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 that time buys you: 6 to 14 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.

234–560

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 vs FloorPulse ▶ Presenter view ↗

Phase 1 of 5

Traditional workflow

FloorPulse workflow

Open any step for the detail behind it, or use Run the job to walk the comparison through.

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.

What FloorPulse does

Grouped the way the videos are — each heading has its own walkthrough. One site license covers unlimited stations and users, with no per-seat counting; the license each part comes with is shown beside its heading.

Supervisor The hub for viewing all things FloorPulse

Core & Insight ▶ Watch · 8:21

Every job on the floor, live — Mailing, Component and Insight jobs on one board, updated within seconds of each scan. No refreshing; the screens are pushed to.
Progress at a glance — trays and pallets done, pieces, skipped trays, trays per hour, estimated time to completion, last activity, and which machines are on the job.
Pallet and tray drill-down — every pallet and its trays with print status; filter by facility type, destination, locale key or ship date.
Destinations view — completed facilities in bold at the top, "2 of 2 done" beside each one. Built for drop-ship.
Several stations, one job — see exactly what each station has produced when three, four or five machines run the same mail.dat.
Multi-segment jobs — a segment summary bar and progress per segment, with drill-down to its pallets and trays.
Skipped trays, listed — every tray left behind on a pallet, per job, for someone to go and find.
Export to Excel — every column of a job's activity, for someone who doesn't have FloorPulse.
Columns from the other modules — with Manifest, what was loaded and departed and on which trailer; with Routing, trays placed and pallets closed at the end of a lane or a palletizer; QC and pQC checks per tray.
Component view — stacks and summaries (stack parents) as they are built, stacks per hour and time to completion for pre-mail.
You decide what reaches the floor — an imported mail.dat waits as an Available Import until a supervisor makes it a job.
Job lifecycle — Live, Done, Completed and Archived. Done and Completed jobs leave the stations' lists but stay in every report; Archive is the permanent, read-only record.
Corrected mail.dat, handled — a newer file for a job with no production replaces it; a job already in production is protected, and the correction is picked up automatically the moment the job is set to Done.
Every station at a glance — the home page lists every station, its job, device type and last activity.
Alerts on every screen — disk, memory, database, failed imports, unreachable printers and slow operations, pushed to every browser. If the server itself drops off the network, it says so, rather than blaming every printer and station.

Mailing Station Tracking final USPS mail

Core ▶ Watch · 8:46

Scan a piece, the tray tag prints — FloorPulse finds the piece's tray and pallet in the mail.dat and prints that tray's tag on demand. One tag per tray.
A rescan never prints a second tag — scanning another piece from the same tray shows the tray as already printed. A replacement tag is always a deliberate Reprint.
The pallet placard prints itself — the last tray of a pallet triggers its placard. No manual step.
Skipped trays caught — move on to the next pallet with a tray unprinted and the station stops to ask. Print the placard anyway and the skipped trays are listed on its back; scan the tray later and the skip clears.
The production report, on screen — the paper report operators mark off, made electronic: a green bar follows the current scan, and the trays coming up are in view.
Reprint at the station — a damaged or lost tag is reprinted from the tray row; no walk to data processing. Can be switched off per site.
Pick any printer, any time — any tag printer and placard printer on the network, changed on the fly. Walk the floor with a tablet and a Bluetooth scanner and print at the nearest one.
Forward or reverse — per station, to match how the equipment delivers the mail.
Several stations on one job — every station sees the others' trays and pallets live, and is warned when a tray another station already printed turns up.
Ordered or unordered — a pallet panel for trays that come off the line in any order: progress per pallet, a "preliminary — not for postal use" placard to organise the floor, a final placard on demand, and an incomplete-pallets report.
Any mail.dat field as a column — 20+ columns, drag to reorder, saved per device. If it's in the mail.dat, it can be on the screen.
Pallet peek — every tray on the same pallet, including trays from other segments that share it.
Equipment and Routing — name the machine the station is working (optional), and route trays to a lane when Routing is installed.
Any scanner — Bluetooth or USB scanners, Android handhelds, or the device's camera. If the window loses focus, a banner says so before a scan is lost.
Screen Preview printer — tags drawn on screen at true size, for training and client approval without using label stock.
Stations name themselves — a station registers the first time it connects; give it a friendly name ("Inkjet East Tablet") and that name is used everywhere.

Component Station Tracking pre-mail

Core ▶ Watch · 8:22

Mail that isn't mail yet — statements, invoices and VDP letters at the printer, press, folder, cutter or inserter, tracked before they reach the mailing machine.
Your equipment, your names — set up each machine once; the station is an assignment, not a driver.
Stack tags from two scans — scan the first piece of the run once as its anchor, then the last piece of each stack. FloorPulse works out the trays in the stack and prints its tag. Forward or reverse is worked out for you.
Summary placards — the cart or pallet of stacks gets a summary listing every stack on it, printed automatically after a set number of stacks (1–200) or closed early with one tap.
Wrong-product alerts — yellow when the destination changes, orange for a new segment, red for a different job: stop, wrong product.
Presort sequence number — an optional number pad after each scan replaces the paper log kept at the machine.
Reprints without a dialog — rescan a piece from a stack already recorded and it is flagged as a reprint (R for the whole stack, r for part of it) and keeps its sequence number.
Roll Back and Reset — back up to any stack and re-run from there, or reset one station's work for the job and leave the other stations untouched.
Destroyed Report — the stacks that must be pulled and destroyed, grouped by summary pallet; QC and end-of-lane scans flag them on the spot.
New starting point — jump to a different range mid-run; the section built so far is closed into its summary.
A ledger of every scan — machine, time, sequence number, tray range and pallet, with selectable columns and a reprint on every row.
The supervisor sees it too — stacks done, stacks per hour, estimated completion and which machine to go ask.
Routing-ready — a component station can feed the Routing module like any other station.
Built for a phone at the machine — portrait layout, with Bluetooth, USB or camera scanning. Codes that aren't piece barcodes are turned away before they cause confusion.

FPN Insight & Production Visibility Using your existing tray tags and pallet placards

Insight · included in Core ▶ Watch · 2:23

Visibility without changing how you print — the tray tags and placards you already print with your presort software are tracked and reported like live-printed jobs. Nothing is printed.
Placard first, then the trays — scan a pallet's placard to open it, then its tray tags. FloorPulse counts down the trays still to check.
Tray Nesting Error, on the spot — a tray on the wrong pallet is flagged with the pallet it belongs on and that pallet's destination, and stays on a carry list until it is scanned where it belongs.
Missed trays as skips — optionally, trays left unchecked on a pallet the operator moved on from count as skipped until they are scanned.
Full validation — the operator is told when every tray on the pallet has been accounted for.
On the Supervisor board, live — a Verified column with green checks as the floor works, and its own pallet and tray drill-down.
A report for your customer — the production quality report shows every tray verified on every pallet; print it to PDF and send the clean bill of health.
Missing tag or placard, replaced — with a printer set up, reprinted from the QC Inspector, recorded as a reprint and never counted as production.
Any device — PCs, phones, tablets, handheld scanners; USB, Bluetooth, built-in or camera scanning, or type the barcode.
Preprinted and live side by side — with Core, run jobs (or pallets) either way on the same floor.

Manifest Loading it all onto trailers

Add-on module ▶ Watch · 3:38

The right pallet on the right trailer — scan a pallet's placard with a hand scanner and it is loaded to the trailer assigned to that job; a pallet that doesn't belong there is stopped.
Trailers at dock doors — each visit from Arrived to Loading, Closed and Departed, with dock door, trailer number, seal and carrier — all optional.
A manifest for the driver — everything loaded, printable as a PDF; a bill of lading number you supply is carried on it.
Load rules your way — refuse, warn, or allow a supervisor's override with a reason; pallets not closed, or already on another trailer, are caught. A wrong code is refused rather than loaded.
Every kind of pallet — mail.dat pallets, component product going to another building or company, commingle and CoPal.
Dock Board — every closed pallet of every type with the barcode the dock scans, printable one per page. For CoPal and commingle pallets, it is the placard.
Follow a job — every trailer and manifest a job went out on, and what is in each.
When a trailer is lost — mark it destroyed or partly destroyed and the loss report reproduces exactly what it carried.
Exception handling — pallets that come back or must be removed, recorded with who and why.
Shipping export — daily close and transaction files for the systems downstream.
On the Supervisor board — a trailer-status column showing each pallet's latest load or departure.

QC Inspector How to know it's where it should be

Core & Insight ▶ Watch · 1:31

Scan anything — a piece, tray or pallet barcode shows its job, the human-readable barcode, its tray, its pallet, destination and print history.
Reprint from the scanner — the tray tag or the pallet placard, right from the lookup.
Identify a loose tray — a tray with no tag is identified from any piece in it.
Does this tray belong on this pallet? — every tray on the pallet listed below the lookup.
Placement mode — the pallet number in big type for the person at the end of a conveyor: scan, read, place.
Every check recorded — each lookup is logged with station and time, marked QC on the Supervisor board and listed in the Job Audit.
Multi-station placements — with Routing, a tray placed at more than one position shows them all, and the reprint carries the position you pick.
Affordable hardware — a handheld scanner, a phone or a tablet, with camera scanning built in.

pQC — Pallet QC Validate a pallet's tags and placards

Core, Insight or Manifest ▶ Watch · 1:34

Check a whole pallet without loading it — the first scan (its placard, or any tray, piece or stack on it) starts the check.
Right or wrong, at a glance — every scan after it is judged against that pallet: green for same pallet, red for a different pallet naming where it belongs, grey for not found. The whole screen flashes.
Catches the spare placard — scan the placard on every face; a spare pulled off a preprinted stack, the one that sends a pallet to the wrong truck, shows up red.
Readable across the dock — job, pallet, trays, pieces, destination, closed or not, and the trailer and manifest it's on.
Every scan is evidence — green or red, each is recorded; the Job Audit lists every check scan by scan and the Supervisor marks the trays pQC.
Look, don't touch — read-only: nothing is loaded, printed or placed.
Inexpensive kit — shown on an Android phone with a ring scanner.

Reports & Exports What good is data if you can't use it?

Reporting add-on · Floor Pulse report on every install ▶ Watch · 9:52

Floor Pulse report — a timeline of every station or job: line height is throughput, line colour is how steady the run was, so a stalled shift shows at a glance. Included with every license.
Job Completion — every live job's percent complete, trays per hour and estimated time to finish, against the counts in the mail.dat. For the production meeting.
Run Rate — trays, pieces and pallets per hour by job and by station, over active production time only, so lunch and changeovers don't distort it.
Station Status — what every station is running, its rate and its last activity.
Skip Trays — trays skipped and never printed, aged across 7 days to a year, by job, station or shift.
Production Quality — what was expected against what was placed and verified.
Spoilage — what rollbacks and station resets are costing, by station and job.
Job Audit — a job's trays, pallets and pieces completed and where, while it is still running; stalls and standing issues attributed to a station and a time.
Chain of custody — every scan of a job, in three copies: yours, a client copy, and a USPS copy. PDF, or the data files as a ZIP.
Forensics — every scan and every event of the process, for the day someone says it wasn't done.
Print or save as PDF — every report, straight from the browser, over the last 8, 24 or 72 hours or a range you choose.
Only the reports you use — hide the ones that mean nothing to a station; the setting is per station.
It's your data — read-only access to the live production database, to report on and query as you like.

Help, Manual & Training Support is top priority

Every license ▶ Watch · 6:25

Help on every page — context-specific, at summary level with detail beneath, and with videos built in.
English and Spanish — chosen per station, so one operator's choice doesn't change anyone else's screen.
A complete manual — every help page compiled into one manual with a table of contents, so the two never disagree.
Training by role — assign operators, supervisors or admins a training path through just the parts they need, and let them come back to it.
Troubleshooting written for the floor — common problems and fixes in operators' language, not IT's.
Support when you need it — the support agreement includes 8 hours of support each month (unused hours don't carry over), from US-based people who know the product and the industry.

Under the hood

mail.dat import From any presort software

Drop a ZIP, the job is ready in seconds — a watched folder takes mail.dat from any presort software. A file still copying is never imported half-written.
mail.dat 18-1 through 26-1 — every version from 18-1 to the current 26-1, updated as each new IDEAlliance specification is released.
Files that would mislabel mail are refused — a duplicate piece barcode, a container ID used twice in a job, a placard barcode reused across pallets, or a tray whose pallet isn't in the file stops the import, before a wrong tag can print.
Import log — every import attempt with its outcome: imported, replaced, rejected or failed, and why.
Configurable tray tags and placards — choose which mail.dat fields fill the tray tag's printer line and mailer areas and the placard's detail columns, with a live preview.

Printing & hardware

Zebra — ZPL thermal printing direct to any Zebra on the network.
Microcom — native Microcom LDS printing.
Laser placards with no drivers — any network laser that supports IPP Everywhere; no print server, no spooler.
USPS-compliant tray tags — L-3216A layout, Code 128 barcode at the correct dimensions.
USPS-compliant pallet placards — DMM 204 Exhibit 3.4.3, Intelligent Mail container barcode.
Scanners — any Bluetooth or USB scanner that reads IMb, or the device camera.
Printer discovery — finds printers on your network; test print from the config page.

IT, security & deployment

On-premises, no outbound connections — runs with no internet at all; FloorPulse makes no outbound connections, for updates, licenses or anything else.
One signed Windows installer — FloorPulse as a Windows service with PostgreSQL 17 bundled. Updates back up and validate the database first, and roll back if anything fails.
Backup and restore, verified — scheduled backups, each one proven by restoring it into a test database; restore in one click. Included with every license.
Access by rank, not by account — operators are never interrupted; protected actions ask for a key, and each key can be revoked on its own.
Password recovery without a vendor call — a one-time recovery code, plus a fallback for IT with access to the server.
HTTPS on a private network — its own certificate authority, limited to private addresses, set up once per device (zero-touch on a Windows domain).
Browser-based — nothing to install on stations: PCs, tablets and phones.

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.

∞

a representative scan, every tray

Chain of Custody

Every client walkthrough looks the same — inserters, conveyors, pallets, clean and organized. What separates your shop? Show them the chain. A representative piece is scanned for each tray — the same sampling principle USPS uses when a single scan acknowledges a piece reached the mailbox — and every tray tag printed and pallet placard generated is timestamped, traceable, and queryable from any device on the floor. Scan any piece and see exactly 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: The server runs on a single machine on your local network — a Windows PC or server. Every other device is just a browser pointed at it. 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. mail.dat is the industry standard (DTAC/IDEAlliance) for passing job, container and piece data from presort software to production, and the USPS accepts it for electronic documentation — if your presort software writes mail.dat, FloorPulse can use that file. Every version from 18-1 through the current 26-1, updated as each new specification is released.
Modular: FloorPulse is built as modules. The core platform runs the floor; the rest layer on top as your operation needs them.

FloorPulse Core — supervisor view, Component Station building, and Mailing Stations producing the finalized mail. Includes configuring the Mailer Use areas on tray tags and pallet placards.

Reporting — Floor Pulse, Job Completion, Run Rate, Spoilage, Station Status, Job Audit, and SKIP Trays.

Manifesting — what shipped, and when it shipped.

Integrated Routing — routing driven by your mail.dat jobs, including co-palletization and commingle.

Independent Routing — co-palletization and commingle without mail.dat. Route to your sorters.

Simple deployment

Installs as a native Windows Service with PostgreSQL 17 bundled in — runs on a single Windows machine on your network. The database, runtime, and application all ship in one signed installer, and updates apply in one click with automatic rollback.

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.

Available module: Conveyor Routing

For shops that sort to conveyor lanes and automated equipment, FloorPulse adds lane-and-position routing on top of the core platform. Run it integrated with your mail.dat jobs, or independently for co-palletization and commingle work with no mail.dat at all — route straight to your sorters. Scoped and quoted to your floor — not part of the base license.

What it does

Lane & position assignment — route trays and pallets to conveyor lanes and sortation positions by carrier, service level, mail category, ZIP, CIN, or MID
End-of-line "where does this go" — shows the destination lane and position at the end of the line, on a tablet, a dedicated EOL screen, or a PLC sign
Multi-carrier barcode parsing — reads USPS (IMtl / IMcb), UPS, FedEx, DHL, and Amazon labels
Load distribution — spread a separation across a pool of positions by rotation or split (volume, coverage, count, or time balance)

Automation-ready

Live-Board — real-time visualization of every lane and position across the floor
Controls / PLC integration — a socket API lets palletizers, robots, and end-of-lane controllers request routing decisions and report batch completion
Force-close & placards — close a pallet early from an operator button, a robot, or a lane bypass; the placard always reflects the mail.dat with skipped items annotated
Custom integrations — controls / PLC and equipment integrations are scoped and quoted per project

See it in action

Supervisor — Where all the data goes to be seen