On-premises production visibility for mail service providers.
Windows Server or Windows 10/11. No cloud dependency.
.key file
we emailed you (a demo key works too). FloorPulse is not a demo or freeware.
Contact us to license FloorPulse for your site.
Newest first. Select a release to read what it contains.
FloorPulse gives a mail service provider live visibility of production, from the mail.dat file to the truck.
FloorPulse is 100% on-premise software. It needs no access to the internet. It runs on one server inside your building, and every station, supervisor screen, PC, tablet, phone and handheld scanner uses a web browser on your own network. Nothing is sent outside it.
FloorPulse is licensed per site, not per seat: FPN Insight or FPN Core, plus optional Reporting, Manifest / Shipping and Integrated Routing add-ons. Each product below says which license includes it.
Included in: FPN Insight and FPN Core.
Insight tracks the tray tags and pallet placards you already print with your presort software. Nothing is printed; every tag is checked against the job's mail.dat and recorded, so preprinted jobs are tracked and reported the same way as jobs printed live.
Scan a pallet's placard to open it, then scan its tray tags. FloorPulse counts down the trays still to check on that pallet, so the operator sees at a glance what is missing.
A tray scanned onto the wrong pallet is flagged on the spot with the pallet it belongs on and that pallet's destination. Insight keeps a list of trays to carry to their correct pallet until each one is scanned where it belongs.
Insight runs in a browser on a PC, phone, tablet or handheld scanner. Scan with a USB or paired Bluetooth scanner, an Android handheld with a built-in scanner, the device's camera, or type a barcode by hand. Operators can switch between pallets and come back to one at any time.
When a printer is set up, a missing tray tag or pallet placard can be reprinted from the QC Inspector. A reprint is recorded as a reprint and never counts as production.
Insight jobs have their own row on the Supervisor board with pallet and tray drill-down, and appear in the reports (with the Reporting add-on) alongside jobs printed live.
A setting can count trays left unchecked on a pallet the operator moved on from as skipped, so they show on the Supervisor board and in the reports until they are scanned.
Included in: FPN Core.
Core adds live tag and placard printing at the Mailing station, Component production tracking before the mail is finished, and the Supervisor board, on top of everything in Insight.
Drop the mail.dat ZIP your presort software already produces into a watched folder. FloorPulse reads DTAC/IDEAlliance versions 23 to 26, waits until a file has fully arrived, and checks it before anything reaches the floor. Several files dropped at once are handled side by side.
When a corrected mail.dat arrives for a job that has not started, it replaces the old one. If production has started, the revision waits; when the supervisor marks the original job Done, the newer file is picked up automatically. Nothing printed needs recalling, because nothing was printed ahead of time.
A file that would put the wrong tag on a tray, such as one barcode on two trays or a container number used twice, is refused at import with the reason, rather than discovered on the floor.
Imported files wait under Available Imports until a supervisor creates the job. Jobs move from Live to Done to Archived, and stations only offer Live jobs.
Every import is recorded with its outcome and the reason for any refusal. The Mail.dat Reviewer lets you browse the imported file itself, by file type, with sorting and filtering.
At the Mailing station the operator scans any piece; FloorPulse finds its tray in the mail.dat and prints that tray's tag at the nearest printer. There are no preprinted stacks to sort and no wrong tag in the wrong tray.
A tray's tag prints once. Scanning another piece from the same tray shows the tray without printing again; a new tag is always a deliberate Reprint.
When the last tray of a pallet is tagged, its placard prints automatically. A preliminary placard, marked not for postal use, can be printed at any time to organise the floor.
A pallet that has to ship short can be closed early. FloorPulse prints the placard with a list of every tray not on it, so the shortfall is documented rather than discovered.
When trays should come off in presort order, a tray passed over is flagged at the station and on the Supervisor board as it happens, and stays flagged until it is printed.
Any number of stations can work the same job. Each sees the others' trays marked printed immediately, and a pallet being built at one station is locked to the others.
When a station stops mid-job, another station can take over all of its work, including unfinished pallets, after a short countdown the original station can answer.
Every network printer is available to every station. A pallet builder with a tablet and a Bluetooth scanner can walk the floor and print to the closest printer.
When more than one process is needed to complete the final mail package, Component tracks each of those steps and shows their status to anyone using the Supervisor screen. Operators at the folder, inserter, cutter or other equipment scan pieces to confirm the job, segment and destination they are running, and a colour-coded alert warns of a destination, segment or job change.
Each stack of in-process work gets a tag, and a summary placard lists every stack on a pallet, so component work is accounted for before it is combined.
A bad run can be rolled back to any stack and re-run, or one station's work on a job reset, with every other station's work untouched. A printable Destroyed report lists the material to pull.
Scan any piece, tray or pallet barcode and see the job, the container, where it belongs, and its print history. Placement mode shows the pallet number in large type for the person placing trays at the end of a line.
Tray tags and pallet placards can be reprinted from the Mailing station, the QC Inspector or the Supervisor board. Reprints are recorded separately from original prints.
Every job's progress on one screen, updated as scans happen, with drill-down from job to pallet to tray and Excel export at each level. Skipped tray counts show at job and pallet level.
Tray tags follow the USPS L-3216A layout and pallet placards DMM 204 with the Intelligent Mail container barcode. Which mail.dat fields appear on each is configurable, with a live preview against your own data.
FloorPulse prints directly to Zebra and Microcom thermal printers and to laser printers that support IPP Everywhere, with no print server or drivers. Printer health is checked before printing, and a tag that fails to print is never recorded as printed.
Operators are never asked to sign in. Changes are protected by named keys at ranks you define, such as Supervisor or Data Manager, each key revocable on its own. A recovery code and an IT recovery path mean a forgotten password is never a dead end.
Scheduled database backups are each restored into a scratch database and checked before they are counted as good. Any backup can be restored from the Configuration page.
The landing page shows the server's health, disk, memory, database and power settings. Alerts appear on screen when something needs attention, such as low disk space or a server that could go to sleep.
A read-only database account lets your own reporting tools, such as Excel or Power BI, query production data directly from any PC on your network.
A Training page takes new operators and supervisors through each screen and records their progress. Every page has a Help panel, and a searchable manual covers the whole product.
A single signed Windows installer sets up FloorPulse as a Windows service with its database included. Every PC, tablet, phone and handheld scanner needs only a browser. Upgrades back up the database first and roll back automatically if anything fails.
FloorPulse needs no access to the internet: it makes no outbound connections and keeps working with the internet unplugged. Your production data never leaves your building. Devices trust the server through a certificate that can only vouch for addresses on private networks, or through your own certificate if you have one.
Included in: the Reporting add-on, with FPN Insight or FPN Core.
Type part of a job number or description to pick any job, live, done or archived. Every report then shows that job across its whole life, however long ago it ran.
Every station's or job's throughput as a pulse line over time, coloured by how steadily it ran, so a stalled shift or a machine that never got going is visible at a glance.
Trays, pieces and pallets per hour for each job, excluding idle time, and how far each job has to go with an estimated finish at the current pace.
Which stations ran, what they produced and on which job, and a timeline of when the work happened and where the gaps were.
For every pallet, what the mail.dat says belongs on it against what was placed, with the shortfall split into skipped trays and trays never produced, because the two are fixed differently.
Trays passed over and not yet produced, by job, station and shift; and a per-job review of what is done, what is incomplete and what needs attention.
Rolled-back and reset material over time, by station, as spoiled trays and estimated mail pieces.
A per-job record of what was scanned, printed, placed and closed, by which station and when, with a separate copy you can hand to your client and one for USPS.
Every report prints cleanly or saves as a PDF in one click.
Included in: the Manifest / Shipping add-on.
Build each trailer's manifest by scanning pallets as they load. FloorPulse checks each pallet belongs on that trailer's destination, and records it on the trailer's manifest as it loads.
Each trailer is tracked through loading, closing and departure, with every change recorded.
Every closed pallet of every build type, with its scan barcode, on one screen at the dock.
Rebuild a collapsed pallet by scanning its loose trays: FloorPulse tells the operator which pallet each tray belongs on, and records every change as part of what shipped.
If a trailer is lost or destroyed, FloorPulse reproduces exactly what was on it.
Included in: the Integrated Routing add-on (requires FPN Core), and FPN Standalone Routing.
Every tray of a mail.dat job is routed to the pallet it belongs on, including CoPal (co-palletization) and commingle work where trays from many jobs and mailers share pallets.
A pallet can be built wherever it makes sense: at a single point at the end of a line, or by pulling trays off the side of a conveyor along its length. FloorPulse handles both, with a handheld scanner telling the operator where each tray goes.
Routing is not only for automated plants. With a simple, low-tech gravity conveyor you can move unsleeved trays away from your production areas and build pallets where the trays arrive. The strapper and the pile of sleeves are needed in one place instead of at every production area. No robots and no multi-lane controls: a handheld scanner points the operator to where each tray goes, and when a pallet is full its placard prints.
Separations by carrier, ZIP, content and mailer decide where trays go. Load can be spread across a pool of positions, and priority work can be given its own tier.
A wall display of every lane and pallet, so everyone can see what is building where.
FloorPulse also integrates with fully automated conveyor controls, palletizers, divert sorters and robots through its API. FloorPulse holds the routing decisions, so the machines never need reprogramming when a routing table changes.
Every FloorPulse installer is Authenticode-signed. Before installing, confirm the publisher and the checksum. In PowerShell:
The hash must match the value above, and the signature status must be Valid with the
signer FLOOR PULSE NET, LLC. If either check fails, do not run the file —
contact us instead.
Under two minutes, start to finish — downloading with your license key, running the installer, and the first launch.
About a minute: open FloorPulse in the browser at https://localhost:5001, set the admin password, keep the recovery code somewhere safe, and drop in your license key.
Run the installer over an existing install to upgrade — it stops the services, takes a pre-upgrade database backup, upgrades, and rolls back automatically if anything fails. Your data is preserved.
To remove FloorPulse, use Settings → Apps. This leaves your database and backups in place. To remove everything, including the database, use the complete uninstall script:
FloorPulse is a new product, and our code-signing certificate is recent. Until enough customers have downloaded a given release, Windows SmartScreen may show “Windows protected your PC” even though the file is signed and safe. This is a reputation warning, not a malware finding.
Verify the signature and checksum above. If they match, choose More info → Run anyway. If your antivirus quarantines the installer outright, please contact us — we want to know, and we report false positives to the vendor directly.
Need an older release, or the MSI instead of the bootstrapper? Contact us.