Patent Publication Number: US-11034143-B2

Title: Systems and processes for producing products having cards attached thereto

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/056,208, filed Sep. 26, 2014, U.S. Provisional Application No. 62/096,035, filed Dec. 23, 2014, and U.S. Provisional Application No. 62/128,625, filed Mar. 5, 2015. The contents of these prior applications are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to sheet products and processes therefor. This invention particularly relates to processes for producing sheet products comprising surface-mounted or applied single- or multi-ply cards attached to a single- or multi-page carrier manufactured from a single, fully-integrated contiguous paper blank, and to products formed thereby. 
     Demand has continued to grow for direct mail advertising. Direct mail, that is, advertising mail products that are directly addressed to the intended recipient, encompasses a wide variety of marketing materials, including brochures, catalogs, postcards, newsletters, and sales letters. These promotional products are designed to convey personalized purchase offers and information to postal or otherwise distributed recipients. In the direct mail advertising industry, there is a growing demand for high quality, standalone, personalized direct mail promotional products that provide customers with redeemable discount offers, loyalty promotions primarily used at point of purchase retail outlets, and/or embedded or non-embedded electronic labels/tags that enable the recipient to be immediately connected via a mobile phone or computer. Increasingly, these promotional products have non-trackable or trackable data usage measurements suitable for providing the direct mail purchasers with closed-loop data feedback regarding the success of their direct mail advertising campaigns. 
       FIGS. 1A through 1F  represents nonlimiting examples of promotional products  10  that carry promotional add-ons, for example, paper cards  12  offering redeemable discounts or loyalty promotions, which are attached to a multi-page carrier  14 . These promotional products  10  typically have high volume, direct mail advertising print formats widely used by commercial retail as high end promotional coupons, redemptions, or loyalty cards. As described hereinafter, promotional cards  12  and carriers  14  of this type are often manufactured by one of two general methods, one being web finished from a continuous fully, partially or non-preprinted web from a web printing press combined with inline or separate stand-alone “offline” web finishing systems, and the other being methods whereby pre-cut cards are individually tipped on, on-serted or placed onto a fully, partially or non-preprinted individual sheet “blank.” Along with established web finishing methods in which cards and carriers are derived directly from a web, “tipping,” “tip-on,” “on-serting,” and “pick and place” methods are widely used and popular methods to attach pre-cut individual cards onto either continuous webs or pre-cut individual carriers. These “card with carrier” manufactured promotional products  10  are some of the most popular and desirable formats in direct mail printing today. 
     Using preexisting inline or offline web printing and web finishing processes, any number of specialty functions can take place in concert during the manufacture of promotional products  10  of the types represented in FIGS.  1 A- 1 F. In a typical inline web printing and finishing process used in the printing industry, one or more fully, partially or non-printed moving web materials pass through a series of printing units at high speeds to be fully or partially printed, dried, and cooled, during which as an immediate and continuous part of the printing process the web undergoes finishing operations such as variable data printing (inkjet), UV coating, folding, perforating, gluing, die cutting, and rotary cutting to produce products having a desired page format, enhancement, and length. The “offline” web finishing version process usually involves concluding web printing and web finishing during a separate, two-step process, wherein the web is printed and rewound as a roll to be later unwound as a pre-printed web into a web finishing line to conclude folding, perforating, gluing, die cutting and rotary cutting the web to final length. 
     As nonlimiting examples,  FIGS. 2 and 3  schematically represent a web printing press  20  with an inline web finishing system  40  of types suitable for producing single-, double- or triple-ply paper products such as the promotional products  10  represented in  FIGS. 1A-1F . Typically, such processes start with a white roll stock paper  22 , often having a gloss or matte surface and a gauge of #50 to 10 pt. The paper  22  is then processed as a continuous web in the direction of travel indicated by arrows  18 . Images are printed on the stock paper  22  using, for example, fixed repeat, web offset, flexography, rotogravure, inkjet, digital, and/or rotary lithography at stations  24  and  26 . The lithograph uses an up/around plate attached to a printing press cylinder (not shown) to produce rotary, fixed images on the web in a repeatable pattern divisible between a plate repeat circumference and a desired final product length, typically having up to five or more repeat images. Wet ink is then heat-set or UV cured in a drying system  28 . Afterward, the temperature of the web may be reduced and/or a surface protection material may be applied at a station  30 . Heat-set, remoistenable adhesives, or aqueous coatings can also be applied at the station  26  or at any time immediately following printing. Pattern perforation or die cutting of the entire continuous web may be performed by a pattern perforation or die cutting system  32 . 
     If the promotional cards  12  carried on the promotional products  10  are to be personalized for direct mailing, a variable data printing (VDP) system  34  including an inkjet system, a laser system, or the like may be used to apply personalized data to any portion of the entire web for each individual product  10  formed by the previous printing processes. The personalized data may include, for example, a recipient&#39;s name and address, a salutation/greeting, maps, etc., as requested by the direct mailing promotion campaign. The VDP system  34  may also be used to apply to what will later become the card portion of the finished product card  12  one or more inkjet or laser printed trackable barcodes such as but not limited to UPC, QR, numeric, etc., as rescan technology allows for data usage measurements. The VDP system  34  may be timed to mismatch the personalization data and the card  12  at this time since the web will be later separated, sent to different paths, and re-married in mismatched timing downstream in the web finishing system  40 . Typically, UV cured or aqueous based coatings may next be applied while the web is wholly intact and still continuous. Many if not all of these processes are typical to the creation and manufacture of web fed paper promotional products. 
     Once all printing has been completed, the entire continuous web enters the inline web finishing system  40 , which is represented with top and side views in  FIG. 2 . The finishing system  40  is represented as having a ribbon (or angle bar) deck station  42  where the web is slit in the running direction (arrow  18 ) into continuous ribbons  44  that may be of equal or unequal widths. Various suitable slitting means are known in the printing industry and can be used. In this representation, the ribbon deck station  42  also often serves to turn the web (ribbons) out ninety degrees relative to its entry into the inline web finishing system  40 . For simplicity, the inline web finishing system  40  will initially be described as producing a single-ply paper product with reference to  FIG. 2 , and multi-ply cards and advanced carriers will be described with reference to  FIGS. 3 and 4 . In  FIG. 2 , the full web is slit or cut at the ribbon deck station  42  to exit the station  42  as two ribbons  44  (top view of the system  40 ), one of which is designated a card ribbon  46  and the other a carrier ribbon  48  (side view of the system  40 ), though it should be understood that the slitting operation is not limited to producing the two ribbons  44  represented in  FIG. 2 . As depicted in the side view of  FIG. 2 , the ribbons  46  and  48  are transferred at separate vertical levels so as to be one above the other within the finishing system  40 , and as represented in the top view of  FIG. 2  the ribbons  46  and  48  may be “shifted” or repositioned laterally for format page imposition. At this time, format determination is made for single- or multi-ply cards  12  as well as the carriers  14 . 
     The single-ply card ribbon  46  is typically positioned as shown in  FIG. 2  to be vertically above the carrier ribbon  48  to produce promotional cards “inline” from a web. The card ribbon  46  passes into and through a rotary die cutter  50 , which is configured to match an overall web press circumference repeat directly or as a whole number multiple thereof. Die plates (not shown) of any shape or size may be mounted around the die cutting cylinder  52 . A similarly sized anvil or back cylinder  54  is located below the die cutting cylinder  52  to provide a rigid interface capable of ensuring that the die cuts are of high, consistent quality. The card ribbon  46  passes between the cylinders  52  and  54  and a card pattern is die cut into the card ribbon  46  to produce a die cut card ribbon  56 . The die plates may or may not contain slight ties or nicks on edges of blades on the die plates in order to perforate, rather than completely die cut, the card ribbon  46 , which allows the cards  12  to be minimally and temporarily held inside the die cut card ribbon  56 . The cylinders  52  and  54  are circumferentially timed to the printed image on the card ribbon  46  such that the shapes and sizes of the cards  12  correspond to an exact position on the card ribbon  46  to match the previously printed image on the web. 
     At the same time, the carrier ribbon  48  to which the cards  12  will be affixed is routed under the cylinders  52  and  54  and immediately directed by path rollers to meet as near as possible to an outgoing rotation point of the cylinders  52  and  54  and the die cut card ribbon  56  which is exiting the cylinders  52  and  54  with the die cut card pattern. On route to a marrying point of the carrier ribbon  48  and the die cut card ribbon  56 , hot melt spot glue from a programmable pattern timed, high temperature, high pressure gluer nozzle  58  is applied to the carrier ribbon  48  at specific locations corresponding to an area, referred to in the art as a carrier specific page location, where each card  12  will be attached to its carrier  14  (which may be a single card or multiple cards  12  mounted to each carrier  14 , as evident from  FIGS. 1A-1F ). The carrier ribbon  48  thereafter immediately meets the die cut card ribbon  56  on the same horizontal or vertical plane and are married together, that is, combined. The die cutter  50 , the gluer nozzle  58 , the die cut card ribbon  56 , and the carrier ribbon  48  are adjusted for circumferential and lateral registration positioning to ensure correct timing between all of the ribbons  44  and finishing processes will correspond so that the content of the print images from the card  12  and the carrier  14  match, and to ensure that the die cut portions of the card ribbon  56  from which the cards  12  are defined will be circumferentially timed to meet the location of the hot melt glue spots on the carrier ribbon  48  in order to provide proper adherence of the cards  12  to the carrier ribbon  48 . 
     After a card  12  carried by the die cut card ribbon  56  is glued to the carrier ribbon  48 , the remainder of the die cut card ribbon  56  is separated from the carrier ribbon  48  and removed as waste  60 . This may be performed with a suction or vacuum system  62  suitable for separating and pulling away the remaining card ribbon  56  through high velocity air flow that exceeds the velocity of the ribbons  56  and  48 . The cards  12  remain on the carrier ribbon  48  and are held firmly in place by the hot melt glue spots which then set and bond. Any perforations in the die cut card ribbon  56 , formed by the ties or nicks of the die plates to reduce a possibility of card fallout and loss during die cutting and or transfer of the die cut card ribbon  56  to the carrier ribbon  48 , are ripped apart as surrounding card waste is separated and vacuumed away by the suction system  62  leaving the cards  12  secured to the carrier ribbon  48  to form a combined ribbon  64 . 
     Stations  66  of the web finishing system  40  represent various other conventional processes that may be used to facilitate the folding of the combined ribbon  64  around the cards  12  in order to complete the width and page count for a postal-ready finished-size product format desired by a print buyer. A rotary cutter-type machine  68  produces a final cut off length on the combined ribbon  64 , which determines the final overall desired product length that matches the image lengths printed into postal-ready finished size. A shingling station  70  performs shingled delivery stacking of the products (that is, the promotional products  10 ) to maintain postal address delivery sequence or at least to provide a general postal sortation requirement. 
     To produce multi-ply cards, the process of die cutting and merging one or more card ribbons  46  to the carrier ribbon  48  with hot melt spot glue and subsequent waste removal remains essentially the same in concept. Differences generally include the creation of modified or additional ribbons from the web, as represented with two alternative web finishing systems  40  depicted in  FIG. 3 . For instance, double-ply cards  12  require that a relatively wider card ribbon  72  exits the ribbon deck station  42 , instead of the narrower card ribbon  46  represented in  FIG. 2 . One-half of the width of the wider card ribbon  72  may be pattern glued by a gluing device  74 , and then immediately folded in half upon itself by a plow folding device  76  to create a two-ply card ribbon  46  (two paper thickness) before entering the die cutter  50 . If a triple-ply card  12  is desired, an additional relatively narrower card ribbon  78  of unprinted, white paper may be produced at the ribbon deck station  42 , shifted into a lateral position, and merged into or sandwiched between portions of the wider card ribbon  72 , as represented in  FIG. 4 . In this case, the entire surface of the wider card ribbon  72  is glued by the gluing device  74  and the narrower card ribbon  78  is merged from above onto one side of the glued wider card ribbon  72 . The merged card ribbons  72  and  74  next pass through the plow folding device  76  which folds the remaining single panel portion of the wider card ribbon  72  over the narrower card ribbon  78  and the remaining half of the wider card ribbon  72  to create a triple thickness card ribbon  46  before entering the die cutter  50 . The remainder of the web finishing systems  40  depicted in  FIGS. 3 and 4  may be the same as that described for  FIG. 2 , and therefore will not be repeated here. 
     As evident from  FIGS. 1A-1F , more than one carrier ribbon  48  may be used to produce promotional products  10 , and the resulting carriers  14  may include many varieties of panel folds to create additional advertising page formats. The configuration of a carrier  14  is often and generally limited by the overall web width from the printing press  20  and perhaps equally so the weight of the final product and cost for postal delivery based on weight. 
     It will be appreciated by those skilled in the art that the above-described printing processes include a very intense series of processes that require mastery of the operational art along with extensive “make-ready” times, a term of art that refers to the process of setting up a printing system before running a job. The make-ready requirements of the above-described printing processes also result in paper waste during make-ready, which in addition to running (operational) paper waste during production runs result in costs to print buyers that are prohibitive at lesser volumes, reducing the availability of direct mail products. 
     Additional conventional techniques for producing promotional products of the type represented in  FIGS. 1A-1F  include creation of individualized cards  12  from paper or PVC (plastic), which can be added to a running inline or offline web finishing process or more popularly onto individual separated conveyed pieces from a variety of mailing machines available to the mailing/finishing/fulfillment industry segment. Such cards  12  are attached to their carriers  14  during the finishing process by such methods as “on-serting,” “on-setting,” “tip-on,” “tipping,” “affixing,” and/or “pick and place” techniques using dedicated machines or feeders for in-time “tip-on” placement of the cards  12  to the carriers  14  (a web or individual piece) conveyed below the machine or feeder. However, these methods also provide significant limitations and negative aspects. For example, relative to paper cards, plastic cards often have higher material costs, are more costly to print, are of differing paper or print quality, are of differing color match, and cannot be printed on a back side after being attached to the web carrier sheet or blank, as well as other well-known limitations. In addition, these methods typically involve a multi-step process to complete finished card/carrier formats, including but not limited to separate printing of carriers  12 ; separate printing of cards; separate cutting of carriers to final size; separate die cutting and matrix removal around cards; sometimes separate process for VDP onto cards; all resulting in costly additional processes and handling. Regardless of the manufacturing method (e.g., continuous web/ribbon processes, web tip-on; or sheet/blank tip-on methods), in all known existing production circumstances, cards are always completely and physically separated from carriers at some point during the process which results in additional finishing sequences, steps, handling, limitations to product design, and a potential for circumferential and lateral misregistration and graphics mismatch of the card  12  to carrier  14 , as well as speed reduction in finishing. However, most significant errors are likely to occur from the potential disruption of the postal sortation sequence to mailing order and customer receipt of mismatched data and information. The latter issues always demand investment for expensive camera verification technology to “read/write” VDP sequences during reassembly of the card to carrier to ensure data match and sequencing for client and product recipient. 
     In view of the above, it can be appreciated that there are certain problems, shortcomings or disadvantages associated with direct mail products that carry promotional cards, and that it would be desirable if systems and processes were available that were capable of at least partly reducing the complexity of the manufacturing process, reducing make-ready time, and reducing waste common to conventional manufacturing processes typically used to produce such direct mail products. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present invention provides systems and manufacturing processes suitable for producing products comprising surface-mounted or surface-applied single- or multi-ply cards attached to a single- or multi-page carrier manufactured from a single, fully-integrated blank (fully, partially or non-preprinted). The processes provide for reduced complexity of the manufacturing process, reduced make-ready times, and reduced waste relative to conventional manufacturing processes for producing comparable products. 
     According to one aspect of the invention, a process of manufacturing a finished, mail-ready product having a carrier and at least one card secured thereto includes providing a single, individual, contiguous blank having images or text printed thereon and at least first card panel and a first carrier panel that are contiguous with a fold line therebetween. The process further includes cutting the first card panel to at least partially define a first partial cutout card area therein such that the first partial cutout card remains partially attached area to the first card panel and a first remaining portion of the first card panel surrounds the first partial cutout card, folding the first card panel over and onto the first carrier panel such that the first partial cutout card is secured to the first carrier panel with an adhesive, and removing the first remaining portion of the first card panel so that the first remaining portion is separated from the first partial cutout card, the first partial cutout card remains secured to the first carrier panel and defines at least a portion of the card of the product, and the first carrier panel defines at least a portion of the carrier of the product. The card and carrier are never physically separate or out of contact with one another throughout the process. 
     According to another aspect of the invention, a system for producing a product having a carrier and at least one card secured thereto includes means for performing each of the steps of the process described above. 
     A technical effect of the invention is the ability to manufacture products having one or more single or multi-ply cards secured to a single or multi-ply carrier, wherein the carrier and the card(s) attached thereto can be produced from a single integral blank, as opposed to a continuous web. In particular, it is believed that, by forming the card and the carrier from the same integral blank with the card being secured in some manner to the carrier at all times in the manufacturing process, any images, text, personalized data, or other printings on the carriers and the cards will match without the need of any camera system, verification equipment, or other tracking or timing techniques, which are ordinarily required by conventional web printing techniques and any other processes that involve separated cards and carriers, therefore requiring matching and combining cards and carriers in later stages of the manufacturing process. 
     Other aspects and advantages of this invention will be better appreciated from the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1F  represents promotional products having a variety of direct mail formats and cards of various shapes, sizes, and configurations attached thereto. 
         FIGS. 2-4  represent an exemplary web printing press and exemplary inline web finishing systems of types suitable for manufacturing the promotional products including those of  FIGS. 1A-1F . 
         FIG. 5  represents a system and stations thereof that are suitable for performing the steps of  FIGS. 6-10  in accordance with aspects of the present invention. 
         FIGS. 6A through 6F  represent steps of a manufacturing process for producing a promotional product having a card attached thereto in accordance with a nonlimiting embodiment of the present invention. 
         FIG. 7  represent a nonlimiting promotional product of a type that can be produced by the manufacturing process depicted in  FIGS. 6A through 6F . 
         FIGS. 8, 9A -C, and  10 A-B represent steps of alternative manufacturing processes for producing different types of promotional products having a card attached thereto in accordance with nonlimiting embodiments of the present invention. 
         FIGS. 11 and 12  represent exemplary stations that may be used in conjunction with a waste removal station of the system represented in  FIG. 5 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention generally provides manufacturing processes for producing single- and multi-ply products that may be of essentially any size, quantity, and shape. The products include a carrier having one or more cards secured thereto that differ in size from the carrier, and each product is preferably individually produced entirely from a single, individual, fully integrated (contiguous) blank (i.e., substrate) that optionally may be partially or fully preprinted from any conceivable print engine source to have images pre-printed thereon. Products produced by the processes described herein may optionally include individual personalized data for recipient personalization and postal delivery sequencing directly on or across any or all parts of the blank. Notably, cards and carriers of the products are produced from the single blank and are never physically separated from the blank during the manufacturing process. 
     According to certain aspects of the invention, the manufacturing processes described hereinafter are capable of substantially replicating promotional (direct mail) products produced from paper, including those represented in  FIGS. 1A-1F  that were previously produced by conventional web press/inline/offline finishing processes such as those represented in  FIGS. 2 through 4 , as well as a large variety of other equipment and processes capable of on-serting, on-setting, tip-on, tipping, affixing, and/or pick and place techniques commonly employed to attach separated individual cards to carriers. Generally, such promotional products can be produced using a system having aspects in common with folder/gluer lines of the type used in the folding carton box converting industry to finish promotional products. In addition, such promotional products can be produced from high quality printing materials by processes that can be configured to maximize efficiency, time, and/or cost savings while reducing waste relative to conventional methods. The manufacturing processes described herein are further believed to address a growing print buyer demand for production of highly value-added promotional products at reduced quantities by providing for lower quantity runs at reduced cost relative to conventional methods. 
     While the invention is particularly well suited for producing promotional products for reasons as described above and will be discussed below in reference to such products, the invention is not limited to promotional products or to any particular material from which such products may be produced. In particular, though the invention will be described hereinafter in reference to promotional products of types generally used for direct mail advertising campaigns, it will be appreciated that aspects of the present invention are directly applicable to a variety of other products such as, but not limited to, post cards, greeting cards, and cards used for playing, trading, collecting, and games. For example, processes disclosed herein may be used to produce single- and multi-ply trading cards comprising cards surface mounted to an integrated carrier. Simplex and duplex variable data printing (VDP) may be used to apply trackable or non-trackable digital tags, stickers, labels, etc., outside of or within layers of plies used to create the trading cards (or other product). Digital tags, NFC (near field communications), and RFID (radio frequency identification) are nonlimiting examples of what may be used to link the products with electronic devices to expand a user&#39;s interaction and experience. Digital tags, stickers, and/or labels may be applied to a blank prior to or during processing to be conspicuous (external) or inconspicuously embedded within layers or plies that create the product, and to further enhance value-added and interactive user capabilities and create direct digital interactivity useful for direct mail, trading, collecting, promotions, coupon, etc. As known in the art, VDP may be monochrome or partial, single, or full color, and may be of any quality (including photo) that can be produced by available methods, including digital laser, inkjet, or other variable print methods. VDP may also be used to apply trackable or non-trackable barcodes, alphanumeric I.D. codes or sequences, addresses, data, etc. 
       FIGS. 6-10  represent nonlimiting examples of promotional products and processing steps that may be employed to produce such products in accordance with aspects of the present invention, and  FIG. 5  schematically represents a system  200  adapted for use in such processes. To facilitate the description of the manufacturing processes provided below, the terms “lateral,” “front,” “behind,” “side,” “lower,” “higher,” “about,” “below,” “right,” “left,” etc., may be used in reference to the perspective of the orientation of the system  200  represented in  FIG. 5 , and therefore are relative terms and should not be otherwise interpreted as limitations to the performance of the manufacturing processes or as limiting the scope of the invention. For convenience, consistent reference numbers are used throughout the drawings to identify the same or functionally equivalent elements. 
     The system  200  represented in  FIG. 5  is in part effectively adapted to replace the web finishing systems  40  of  FIGS. 2 through 4 . The system  200 , which may be referred to as a folder/gluer line, is particularly configured for producing single- and multi-ply promotional products from single, individual, fully integrated (contiguous) preprinted or non-preprinted blanks (substrates)  100 , nonlimiting examples of which are represented in  FIGS. 6 and 8-10 . As used herein and consistent with its general meaning in the printing industry, the term “blank” does not refer to the absence of printing or images, but instead refers to a cut-out or otherwise individual substrate ready for gluing and/or folding in a printing process. As such, “blank” refers to an individual article that is not processed by the system  200  as part of a continuous web and therefore, aside from trimming to a desired shape and size, does not require being die cut from a web after attachment of one or more cards thereto. The system  200  is represented in  FIG. 5  as including a feeder station that may comprise a feeder unit  202  and an edge guide unit  204 , followed by VDP stations  206  and  210  that apply individualized data to the blanks  100 , a turnover unit  208 , one or more optional “additions” stations  212 , multiple folding stations  214 ,  216 ,  220 , and  230  (each of which may include a gluing unit  222 ), one or more mid-line die cutters  218 , a “slitting” station  224 , a waste separation station  226  where waste separation occurs, a waste evacuation system  228 , and a “postal-ready” station  232 . In general, as represented the system  200  is configured to convey, VDP image, flip, on-sert, fold, glue, die cut, slit, and shingle/stack the blanks  100  in order to produce the final products, such as but not limited to the promotional (direct mail) products  10  of  FIGS. 1A-1F , as well as a nonlimiting example of a promotional product  10  schematically represented in  FIG. 7 . For convenience, identical reference numerals are used in  FIG. 7  to denote the same or functionally equivalent elements described for the products  10  of  FIGS. 1A-1F , i.e., a card  12  mounted to a carrier  14 . 
     As will become evident from the following discussion, the product  10  is representative of single-ply and multi-ply promotional products that can be produced by manufacturing process steps represented in  FIGS. 6 and 8-10 . While the system  200  is represented in  FIG. 5  as comprising certain stations, units, etc., as noted above, it should be understood that the invention encompasses systems that could comprise fewer or additional stations, units, etc. Furthermore, there are many variations in how and in what sequence certain operations may be performed, and various hybrid executions are foreseeable. For example, VDP may be performed with a roll-fed (web) or sheet-fed press, and performed partially or entirely within one or more of the folding stations  214 ,  216 ,  220 , and  230 , etc. Similarly, blank and/or card creation may be performed with one or more die cutters located at the entry to one or more of the folding stations  214 ,  216 ,  220 , and  230 , at which point the blanks  100  may be individual sheets or portions of a web, for example, a sheet-fed printing press or a web printing press could directly feed a rotary die cutter to cut the blanks  100  immediately before feeding the blanks  100  directly into the first folding station  214 ,  216 ,  220 , or  230 . 
     Promotional products in accordance with aspects of the invention may be initially preprinted by applying images to a sheet or web using any printing means known or developed in the art, such as but not limited to a fixed repeat rotary sheet fed offset, web fed offset, digital, inkjet, flexographic, rotogravure or other type of printing press, as well as hybrids of any combination thereof. Printed sheets may have an approximate finished size of typically 1, 2, 3, 4 or 5 up/around, but can be any multiple of repeat images that fit into a rotary press repeat circumference. Preprinted sheets or a printed web may comprise completely variable images printed from a non-cylindrical inkjet, laser, or any other spray-on ink transfer printing method and specifically delivered sheeted as individual sheets into a receding pile, conveyor table, or other delivery. Printing may include one or both sides of a sheet or web and can include any ink color additions or sequence, UV cured coatings, aqueous coatings in any image pattern or area, or other application known in the art. 
     A particular but nonlimiting example of the above is to position the system (folder/gluer line)  200  immediately and directly following a printing press, which may utilize any print engine technology available and produce from sheet to sheet or roll to sheet a final cut preprinted blank  100  having any suitable format size for producing the intended card(s)  12  and carrier  14 . The cutting operation that produces the blank  100  may take place at the exit of the press, or may take place at the entry of the system  200  or anywhere thereafter prior to a folding operation and therefore within a continuous “inline” blank conveyance and operation. As such, the system  200  is capable of being combined with a wide variety of printing presses and systems. 
     As a particular but nonlimiting alternative to the above, images can be applied to printed or non-preprinted blanks  100  after they have entered the system  200 . Any suitable printing means can be employed to perform any portion or the entirety of the printing operation(s) performed to produce the product  10 . 
     In particular embodiments, portions of a sheet or web that will later form the cards and carriers of the promotional products are preferably printed side-by-side and laterally across the width of the sheet or web, such that blanks formed therefrom, which in the nonlimiting examples illustrated in the drawings are represented by the aforementioned individual integral blanks  100  of  FIGS. 6 and 8-10 , may later be folded to produce the finished promotional products (such as the product  10  of  FIG. 7 ). Preferably, VDP is performed prior to gluing and folding the blanks  100 , but may be performed at any time with or during initial printing operations and/or after a blank  100  has been folded within the system  200 . Other additions to the blanks  100  may be added at any time within the system  200  to enhance the value of the promotional product. 
     The blanks  100  may be sheet-printed onto sheets as completed 1up images requiring no further or additional cutting or trimming prior to introduction into the feeder unit  202  of the system  200 . Alternatively, after printing the printed sheets or web may be cut to yield blanks  100 , each being a desired individual final size, 1up, flat product having one or more flat panels. The blanks  100  may be cut from multi-up sheets or from a continuous web on any cutting machine known in the art, such as but not limited to, a standalone rotary, platen, or any other type of guillotine, reciprocal, rotary, or laser cutting machine, device, or die cutter. As a non-limiting example, the blanks  100  may be cut from a web using the rotary cutter-type machine  68  represented in  FIGS. 2-4  prior to being fed into the feeder unit  202  of the system  200 . Alternatively, the blanks  100  may be cut from printed sheets directly fed into the feeder unit  202 , and subsequently into a rotary or platen die or any other type/method die cutter (not shown) positioned at the entry end of the system  200  as multiple up/around sheets. Bleed and gap trims may be performed to remove waste at the head and foot of each blank  100 . Regardless of what type of system is used to produce and cut the blanks  100 , the blanks  100  are preferably cut to their overall final shape and size prior to being placed on the entry conveyor (for example, prior to the feeder unit  202  depicted in  FIG. 5 ) and prior to entering the VDP stations  206  and  210  and folding and gluing stations  214 ,  216 ,  220 , and  230  of the system  200 . The blanks  100  may be cut to an overall uniform rectangular shape, though optionally one or more panels of each blank  100  may be longer than other panels, creating what will be referred to as a waste extraction flap  108  ( FIGS. 6A-6E, 8A-8B, 9A-9B , and  10 A- 10 C), such that the blank  100  as a whole has an irregular rectangle shape. As will be discussed in reference to  FIGS. 6A-6E , the process of defining a card  12  from a portion of the blank  100  (the portion being referred to herein as a card panel  112 ) results in waste material  110  that surrounds the card  12 . Irregular cutting of the blanks  100  to include a waste extraction flap  108  is believed to significantly facilitate the extraction of the waste material  110  when using certain extraction equipment, for example, a cross-fold-drag-hook-and-lift unit  240  (hereinafter, hook and lift mechanism  240 ) schematically represented in  FIG. 12 . However, a waste extraction flap  108  may be unnecessary if another type of waste extraction technique is used, for example, a vacuum wheel  234  schematically represented in  FIG. 11 . 
     As will become evident from the following description, preparation of the blanks  100  on the system  200  can be limited to die cutting the cards  12  and/or single chop cuts or double cross cuts for bleed trim and/or gap removal, which may optionally include formation of the waste extraction flap  108 , formation of the cards  12  with or without ties  104  to the carrier  14 , and/or formation of folding scores along fold lines  106  ( FIGS. 6A, 8A, and 9C ). If such cutting processes are performed by the system  200 , the bleed and gap trim waste formed by the crosscut is extracted immediately after the blank  100  leaves the die cutter (not shown). Once the blanks  100  have been formed, they are conveyed further into the system  200 . 
     When utilizing blanks  100  with the waste extraction flap  108 , the blanks  100  are preferably oriented and loaded into the feeder unit  202  with an orientation such that, regardless of a need later in the process to flop or turn over the blanks  100  for VDP, label application, on-serting, or any other additional processes, the waste extraction flap  108  will be at a first or leading edge of the blank  100  in the travel direction of the blanks  100  at a point within the system  200  (e.g. the waste separation station  226 ) where waste removal is performed to remove material  110  surrounding the cards  12  after the cards  12  have been secured to their carriers  14 . As such, it will be apparent to those skilled in the art that consideration must be taken during format layout and printing to determine a correct orientation necessary for proper downstream gluing and plow folding of the blanks  100  so as to result in a desired finished product. In addition, consideration is preferably taken for any downstream processes needed to flop or turn over the blanks  100 . As a nonlimiting example, if VDP is to occur on a back side of a portion of the blank  100  which will form a card  12 , the blank  100  may be loaded into the feeder unit  202  of the system  200 , bottom side up (inside of unfolded carrier panels), or facing upward. This orients the blanks  100  for proper VDP pagination, that is, applied in a downward direction towards to the desired imaged surface of the blanks  100  as opposed to performing VDP from below and therefore in opposition to gravity, though such an approach is also within the scope of the invention. 
     The blanks  100  may be fed into the system  200  by any means known in the art, nonlimiting examples of which include driven by a gravity, friction, or suction vacuum feeder wheel (not shown) associated with the feeder unit  202 , which delivers the blanks  100  to an entry conveyor (not shown) and edge guide unit  204 . The blanks  100  can be conveyed through the system  200  at speeds typical to the art, for example, with laterally positioned upper and lower motor driven tapes, belts, and/or rollers along the entire length of the system  200  that convey the individual blanks  100  through the various processing stations and units of the system  200 . These driving methods are well known in the art and therefore will not be explained further herein. 
     According to a preferred aspect of the invention, promotional products processed by the system  200  may include personalized data applied by simplex and duplex VDP, schematically represented by the two VDP stations  206  and  210  in  FIG. 5 . Although VDP of trackable or non-trackable data and any other “value added” product format additions may be applied during printing of the sheets or webs from which the blanks  100  are formed, and therefor prior to the blanks  100  entering the system  200 , such additions may be performed by the system  200 , and in particular prior to the folding stations  214 ,  216 ,  220 , and  230  of the system  200 . This however may add a level of complexity to the process by requiring accurate and intensive “cut and stack” procedures during rotary or platen or any other type/method die cutting of the blanks  100  in order to maintain postal sort sequence throughout the entire finishing process. There may also be additional secondary processes after printing, for example, the addition of foils, mechanical embossing, labels, on-serting, information tracking means such as RFID tags/labels, NFC tags/labels, and/or other information tracking “microchips”, etc. Any of the above additions may also be applied after the sheets or web are converted into blanks  100 . 
     In the example of  FIG. 5 , personalized data may be applied by the VDP station  206  and the ink applied thereby is preferably immediately dried using any drying process known in the art, such as but not limited to infrared (IR) drying. Thereafter, the blank  100  may be turned over with the turnover unit  208 , which may employ any turnover or flopping means known in the art, such as but not limited to a buckle fold/head stop attachment modified, designed or otherwise adapted to flop or turn over the blanks  100 . Turning of the blanks  100  may be accomplished with head to foot, left to right, or right to left methods, as long as the method results in the blank  100  being turned over from top side up to bottom side up in the process. As evident from  FIG. 5 , turning of the blanks  100  allows for VDP on two sides of the blanks  100  with the VDP station  210 . Turning of the blanks  100  may also be used to appropriately orient the blanks  100  for the subsequent folding stations  214 ,  216 ,  220 , and  230  of the system  200 . In addition, turning may be desirable or necessary for other process application equipment employed in the system  200 , for example, label applicators, on-serting, information tracking means such as RFID or NFC labels/tags, etc., which may be applied to either side of the blanks  100 . Such value-added product format additions may be applied at the optional additions station  212  represented in  FIG. 5 . 
     Once all printing, VDP, and application of additions is complete, the blanks  100  undergo folding, gluing, and cutting processes to produce the final promotional product  10 . According to a preferred aspect of the invention, once the blank  100  has been created, a card  12  that is to be applied to the carrier  14  of its promotional product  10  is created from but not initially removed from one or more “card” panels of the blank  100 , such that processing of the blank  100  initially results in what will be referred to as a partially cut-out card  102  in the blank  100 . Each card panel  112  may be perforated such that its partially cut-out card  102  remains secured to its blank  100  with the aforementioned ties  104  to prevent the partially cut-out cards  102  from falling out of the blank  100  during subsequent folding and gluing processes. However, it is also within the scope of the invention that a partially cut-out card  102  could be partially or solely retained by friction, edge contact, static electricity, etc., without the use of ties  104 , and therefore as used herein the term “partially cut-out card(s)” encompasses such possibilities. The blanks  100  are glued and folded in a manner so as to apply the partially cut-out cards  102  in the card panels  112  of the blanks  100  to “carrier” panels of the blanks  100  intended to form the carrier  14  of the promotional product  10 . As represented in  FIG. 8A , if a card  12  is intended to be multi-ply, the partially cut-out cards  102  may be formed in multiple adjacent card panels  112  and positioned across and opposite from one another so that after gluing and folding of the card panels  112 , the partially cut-out cards  102  are aligned (superimposed) and can be glued together to form a single, multi-ply card  12 . Alternatively, as represented in  FIG. 9C , a multi-ply card  12  can be produced by simultaneously forming partially cut-out cards  102  in multiple card panels  112  after gluing and folding the card panels  112 , such that the individual partially cut-out cards  102  are aligned as a result of the cutting operation. Notably, the cards  12  may be cut to have any shape or size, and may be cut to be partially attached to or completely detached from any number of single- or multi-ply bonded material plies formed of any woven or non-woven paper or other material. 
       FIGS. 6A-6F  are representative of a process for producing a single-ply card  12  applied to a carrier  14 . In  FIG. 6A , the blank  100  is represented at step  300  as initially including a single card panel  112  “C” and two carrier panels  114  “A” and “B.” The carrier panel B is contiguous with each of the carrier panel A and the card panel C, with corresponding fold lines  106  defined therebetween. Card panel C includes the aforementioned optional waste extraction flap  108  and has been previously die cut to have a partially cut-out card  102 . The die cutting operation that forms the partially cut-out card  102  can be performed at any time prior to the condition of the blank  100  represented in  FIG. 6B , which shows glue spots  116  as having been applied (for example, by the gluing unit  222  of the first folding station  214 ) to the carrier panel B contiguous with the card panel C. The glue spots  116  are applied at locations that will be contacted by the partially cut-out card  102  after the card panel C has been folded over and onto carrier panel B along a fold line  106  therebetween, as represented by step  302  of  FIG. 6C  (for example, performed at the first folding station  214 ), such that the partially cut-out card  102  contacts the glue spots  116  and is secured therewith to carrier panel B. The remainder of the card panel C surrounding the partially cut-out card  102  does not contact the glue spots  116  and therefore is not attached to the carrier panel B, and as such is capable of being extracted as waste material  110 . 
       FIGS. 6D through 6F  represent further steps performed on the blank  100  produced by step  302  of  FIG. 6C . As will become apparent from the discussions of  FIGS. 8A-B ,  9 A-C, and  10 A-B, the steps represented in  FIGS. 6D-6F  can be common to the card finishing sequences described in  FIGS. 8A-B ,  9 A-C, and  10 A-B, and therefore can be employed regardless of whether the product  10  is single-ply or multi-ply or the manner in which cards  12  are die cut from the blanks  100 . The folding operation of  FIG. 6C  has created an outer folded edge, referred to as a backbone or spine  119 , formed by the combined folded panels B and C. The spine  119  can be removed by slitting the spine  119  (for example, at the slitting station  224  of  FIG. 5 ), as represented in step  320  of  FIG. 6D , resulting in a defined edge  118  of the blank  100 . In addition, because the remainder of the card panel C surrounding the partially cut-out card  102  was not attached to the carrier panel B, this remainder is detached as a result of the slitting operation and the waste extraction flap  108  can be used in step  322  to remove this remainder from the blank  100  as a waste material  110 . Removal of the waste material  110  can be performed at the waste separation station  226  by the waste evacuation system  228  of  FIG. 5 , for example, as discussed in reference to  FIGS. 11 and 12 , such that all portions of the card panel C are removed other than the partially cut-out card  102  attached to the carrier panel B. As the waste material  110  of the card panel C is removed, any ties  104  securing the partially cut out card  102  will tear, such that only the resulting card  12  is attached with the glue spots  116  to the carrier panel B. In step  324 , a fold line  106  ( FIG. 6A ) between the carrier panels A and B is folded (for example, at the folding station  230 ), such that the blank  100  becomes a final promotional product  10  having the single-ply card  12  enclosed between portions of the carrier  14  defined by the carrier panels A and B.  FIG. 7  depicts the product  10  oriented and partially unfolded to reveal the card  12  attached to the carrier  14 . 
       FIGS. 8A and 8B  represents steps of a nonlimiting example by which a double-ply card  12  can be formed and attached to a carrier  14 . As a matter of convenience, the blank is identified in  FIGS. 8A and 8B  with the reference number  100 , though the blank has a physical configuration that is different from the blank  100  of  FIG. 6A . In step  304 , the blank  100  includes two carrier panels  114  “A” and “B,” and two card panels  112  “C” and “D.” The carrier panel B is contiguous with each of the carrier panel A and the card panel C with corresponding fold lines  106  defined therebetween, and the card panel C is further contiguous with the card panel D with a corresponding fold line  106  therebetween. Each of the card panels C and D includes a waste extraction flap  108  and has been previously die-cut to have a partially cut-out card  102  surrounded by a waste material  110 .  FIG. 8A  shows a glue pattern  117   a  that has been applied to the partially cut-out card  102  of the card panel D, which is the card panel  112  located farthest from the carrier panels  114 . Glue  117   b  has also been applied to the waste material  110  of the panel D, avoiding the die-cut surrounding its partially cut-out card  102 . At step  306 , the card panel D is folded over and onto the card panel C (for example, at one of the folding stations  214  or  216 ) so that their partially cut-out cards  102  are aligned (superimposed) and glued together with the glue pattern  117   a  to eventually form a single, multi-ply card  12  (equivalent to the card  12  in  FIG. 7 ). At this point in the process, the configuration of the blank  100  resulting from step  306  is generally equivalent to the blank  100  in step  300  of  FIG. 6A , in that the combined card panels C and D of step  306  is generally equivalent to the single card panel C of step  300 , other than being double-ply instead of single-ply. As such, subsequent processing steps may commence with step  301  of  FIG. 6B , starting with application of the glue spots  116 , and continue to produce a final promotional product  10  having the double-ply card  12  enclosed between carrier panels A and B. Notably, because the waste material  110  of the card panels C and D are bonded to each other with the glue  117   b  as a result of the folding step  306 , the waste material  110  can be simultaneously removed (step  322 ) following removal of the spine  119  (step  320 ) formed by panels B, C, and D, such that all portions of the card panels C and D are removed other than the bonded partially cut-out cards  102 . As the waste materials  110  are removed, any ties  104  securing the partially cut-out cards  102  will tear, leaving the double-ply card  12  on the carrier panel B. Following step  324  ( FIG. 6F ), the resulting product will again have the overall appearance of the product  10  depicted in  FIG. 7 . 
     The order and number of such card cutting, folding, and gluing processes will be dependent on the desired final product. In the embodiments of  FIGS. 6A-6F and 8A-8B , die cuts to form the partially cut-out cards  102  are performed prior to folding, and can be performed prior to the blank  100  entering the system  200  of  FIG. 5  or as one of the initial process steps performed within the system  200 . Alternatively, as represented by the embodiments of  FIGS. 9A-9C and 10A-10B , the partially cut-out cards  102  may be formed in the system  200  following a gluing and folding operation, for example, with the use of one or more mid-line die cutters  218 , and then followed by one or more additional folding and/or gluing steps. 
       FIGS. 9A-9C  represent a nonlimiting example of a process for producing a double-ply card  12  similar to that produced by the process of  FIGS. 8A-8C , modified to form the partially cut-out cards  102  after a gluing step. In  FIG. 9A , the blank  100  initially includes two carrier panels  114  “A” and “B” and two card panels  112  “C” and “D.” In contrast to  FIG. 8A , which depicts a similar four-panel blank  100 , the partially cut-out cards  102  have not been pre-die cut in the card panels C and D during the formation of the blank  100 . In step  308 , a nonlimiting glue pattern  117  is applied to the card panel D to the extent necessary to bond the portion(s) of the card panels C and D in which a partially cut-out card  102  is to be formed. In step  310 , card panel D (again, the card panel  112  located farthest from the carrier panels  114 ) is folded over and onto the card panel C (for example, at one of the folding stations  214  or  216 ) such that the panels C and D contact and are secured to one another by the glue pattern  117 . In step  311 , the partially cut-out card  102  is formed (for example, with the use of one or more mid-line die cutters  218 ) by die-cutting the combined panels C and D, such that the partially cut-out card  102  is double-ply and simultaneously formed in the panels C and D. At this point in the process, the blank  100  produced by step  311  is generally equivalent to the blank  100  resulting from step  300  of  FIG. 6A , in that the combined panels C and D of step  311  are generally equivalent to the panel C seen in  FIG. 6A  except for being double-ply instead of single-ply. As such, subsequent processing steps may commence with step  301  of  FIG. 6B , starting with application of the glue spots  116 , and continue to produce a final promotional product  10  having the double-ply card  12  enclosed between carrier panels A and B. As with the embodiment of  FIGS. 8A-8A , because the waste materials  110  of the card panels C and D are bonded to each other as a result of the folding step  310 , the waste materials  110  can be simultaneously removed (step  322  of  FIG. 6E ) following removal of the spine  119  (step  320  of  FIG. 6D ) formed by the panels B, C, and D, such that all portions of the card panels C and D are removed other than the double-ply partially cut-out card  102 . As the waste materials  110  are removed, any ties  104  securing the partially cut-out card  102  will tear, leaving the double-ply card  12  on the carrier panel B. Following step  324  ( FIG. 6F ), the resulting product will again have the overall appearance of the product  10  depicted in  FIG. 7 . 
     The cards  12  and carriers  14  may be produced to have more plies by simply adding additional panels to the blank  100  and then gluing and folding the panels to increase the final thickness of the card  12  and/or carrier  14 . Folding stations may be added prior to the slitting station  224  to more easily process multi-ply promotional products of three plies or more. As a nonlimiting example,  FIGS. 10A and 10B  represent steps in a process for producing a promotional product  10  having a triple-ply card  12 . As represented, the blank  100  initially includes two carrier panels  114  “A” and “B,” and three card panels  112  “C,” “D,” and “E.” As with the blank  100  of  FIG. 9A , the carrier panel B is contiguous with each of the carrier panel A and the card panel C with corresponding fold lines  106  defined therebetween, and the card panel C is further contiguous with the card panel D with a corresponding fold line  106  therebetween. Additionally, the card panel D is also contiguous with the card panel E with a corresponding fold line  106  therebetween. In step  316 , a glue pattern  117  is applied to the card panel E to the extent necessary to bond the portion(s) of the card panels D and E in which two aligned partially cut-out cards  102  are to be formed. In step  318 , the card panel E (again, the card panel  112  located farthest from the carrier panels  114 ) is folded over and onto the card panel D (for example, at one of the folding stations  214  or  216 ) such that the panels D and E contact and are secured to one another by the glue pattern  117 . At this point in the process, except for the absence of the glue pattern  117  the blank  100  produced by step  318  is generally equivalent to the blank  100  shown in  FIG. 9A , in that the combined panels D and E of step  318  is generally equivalent to the panel D seen in  FIG. 9A  except for being double-ply instead of single-ply. As such, subsequent processing steps may commence with step  308  of  FIG. 9A , starting with application of the glue pattern  117  to the combined panels D and E, and continuing through steps  310  and  311  of  FIGS. 9B and 9C  and then continuing further on through the steps represented in  FIGS. 6B through 6F  to produce a final promotional product  10  having a triple-ply card  12  (formed by the card panels C, D and E) enclosed between the carrier panels A and B. The type of glue and fold sequence performed to bond the combined panels D and E with the third card panel C is commonly referred to a “roll fold” sequence with a unique function being that each panel is fully or partially glued together to create multiple plies. As with the prior embodiments of  FIGS. 8A-8AB and 9A-9C , because the waste materials  110  of the card panels C, D and E are bonded to each other as a result of the folding steps  318  and  310 , the waste materials  110  are bonded to each other and therefore can be simultaneously removed (step  322  of  FIG. 6E ) following removal of the spine  119  (step  320  of  FIG. 6D ) formed by the panels B, C, D, and E, such that all portions of the card panels C, D and E are removed other than the triple-ply partially cut-out card  102 . As the waste materials  110  are removed, any ties  104  securing the partially cut-out card  102  will tear, leaving the triple-ply card  12  on the carrier panel B. Following step  324  ( FIG. 6F ), the resulting product will again have the overall appearance of the product  10  depicted in  FIG. 7 . 
     In view of the foregoing, single and multi-ply partially cut-out cards  102  can be formed in the blanks  100  prior to entering the system  200  ( FIGS. 6A and 8A ) by die cutting the blanks  100  or an entire multi-up press sheet or web from which the blanks  100  are made to produce single and multi-ply cards  12 , whereas multi-ply partially cut-out cards  102  formed in the blanks  100  within the system  200  ( FIG. 9C ) may be die cut with the use of one or more mid-line die cutters  218  to produce multi-ply cards  12 . The mid-line die cutter(s)  218  may be used to die cut single-ply partially cut-out cards  102  while the panels of the blanks  100  are flat, or die cut multi-ply partially cut-out cards  102  after gluing and folding panels of the blanks  100  together into multi-ply thicknesses. 
     The mid-line die cutter  218  may be any type of die cutter known in the art, such as but not limited to rotary and platen die cutters, or laser, or any other type/method capable of making a complete cut or kiss-cut, the latter referring to a technique in which the die cutter cuts to a specific depth through a substrate (e.g., one or more card panels  112 ) while leaving an underlying substrate (e.g., carrier panel  114 ) uncut. The mid-line die cutter  218  may have several locations within the system  200  and include special modifications such as a sidelay adjustable die-cutting cylinder head and specialty transport sections designed to convey under control individual blanks  100  through the rotary cylinder sections. The mid-line die cutter(s)  218  in the form of a rotary-style die cutter may be specifically designed with any circumference to match any product length with repeat, or non-repeat matching mid-line die cutter designs may employ a motor drive system that operates independently of the main drive of the system  200  and may further utilize an “electronic cam profile” cutting cylinder drive or other nonlimiting electronic and/or mechanical technology. As a nonlimiting example, changeable die cutting cassettes, cylinders or sleeve style designs can be employed to allow changes in the circumferential size of a rotary-style die cutter to meet the conveyance of the blanks  100  by promoting the timing and positional accuracy of the blanks with respect to desired die cut locations on the blanks  100 . It is foreseeable that other control and registration techniques could be used to synchronize the die cutter(s)  218  with the blanks  100  as the blanks  100  pass through the die cutter(s)  218  during die cutting of the card(s)  12  or the partially cut-out cards  102  from which they are formed. In the case of a rotary-style die cutter, an independent motor drive system may include separated drive motors for a die cutting cylinder and opposing anvil cylinder, and/or for a conveyance drive carrying the blanks  100  through the die cutter  218 . Other types of die cutters commonly used in rotary die cutters include commercially available flexible magnetic die using a magnetic mount die cylinder or a solid type die screw lockdown style made normally of steel or composite materials. Mid-line die cutters  218  for use in the system  200  may also be used in multiples to separate x and y axis cutting, and/or portable and moveable to allow the cards  12  to be die cut to any shape or thickness. 
     According to an aspect of the invention, the mid-line die cutter  218  forms the partially cut-out cards  102  immediately prior to the gluing and folding operation by which a partially cut-out card  102  formed by one or more card panels  112  is semi-permanent fixed to the one of the carrier panels  114  prior to removal of the waste material(s)  110 . As apparent from the forgoing discussion of  FIGS. 6A-6F ,  FIGS. 8A-8B, 9A-9C, and 10A-10C , such a process may involve any number of card panel gluing and folding processes prior to the die cutting operation, and the die cutting operation may be made through any number of previously folded card panels  112  (plies). 
     According to another aspect of the invention, the partially cut-out cards  102  may be formed by the mid-line die cutter  218  after all folding and gluing operations have been performed on the panels  112  and  114  of the blank  100 . In such situations, all card panels  112  to be glued and folded, including the final fold onto the spot glues  116  of the card panel  112  or panels  112  bearing what will be the partially cut-out cards  102 , occurs before any die cutting operation takes place. The cards  12  are only thereafter die cut from the card panels  112  using the mid-line die cutter  218  set to a specific depth and pressure adjustment to cut through only the card panels  112  while leaving the underlying carrier panel  114  uncut. Such a kiss-cutting technique eliminates the need to perforate die cut the card panels  112  immediately prior to the final fold-over of the card panels  112  at the score line  106  onto glue spots  116 , and instead the cards  12  are completely separated from the card panels  112  with a single cut after all folding and gluing operations have taken place. 
     The use of scores or another technique, such as cut scores or perforations formed by channel, crush, or other methods, is believed to be advantageous to the folding processes within the system  200 . When single-ply cards are produced (e.g.,  FIGS. 6A-6F ), high accuracy matching of folding panels may not be required and therefore scoring may not be necessary. When multi-ply cards are produced (e.g.,  FIG. 8A-8B, 9A-9C , or  10 A- 10 B), folding accuracy is critical to ensure that the partially cut-out cards  102  and/or card panels  112  are located in the desired lateral position, especially when multiple partially cut-out cards  102  are to be combined to form a multi-ply card  12  (e.g.,  FIGS. 8A-8B ). In such situations, initial die placement and scoring position accuracy along fold lines  106  directly between the card panels  112  may be of utmost importance. Notably, if the blanks  100  were not previously scored during the blank formation process, it is entirely possible and viable to score the blanks  100  with an appropriate scoring unit included in the system  200  using any process known in the art. As such, scores may be formed within fold lines  106  on an entire multi up press sheet, web, or blank  100  at any time or any place while the sheet, web, or blank  100  is flat and yet to be glued and/or folded. Although not required for single-ply card formats, scoring or perforation is typically preferred to provide overall general product quality when folding heavy gauge paper stock. 
     Folding operations performed by any one or more of the folding stations  214 ,  216 ,  220 , and  230  of the system  200  are preferably performed with a plow fold blade designed “down” and the folding panel being folded upward and over. However, the system  200  can be configured for “up” fold orientations, i.e., opposite the prior description, loading and format procedures remain the same and may eliminate blank flopping or turn over. Regardless, methods of production for both “up” and “down” fold orientation are within the scope of aspects of the present invention. 
     Single- and multi-ply cards  12  of promotional products  10  produced with the system  200  will typically be glued to one of the carrier panels  114  during the final folding operation (e.g., at folding station  230 ) with one or more spots  116  or other suitable pattern of a hot melt glue using any gluing system known in the art, such as but not limited to a rotary, mechanical, pattern programmable electronic slot head, extrusion, spray, or other for hot melt or cold glue station. While shown in  FIG. 6B  as applied to one of the carrier panels  114 , the glue spots  116  may be applied to the side of the partially cut-out card  102  facing the carrier panel  114 . The glue spots  116  are preferably sequenced and timed to be precisely applied to the carrier panel  114  in one or more locations so that the partially cut-out card  102  will contact the glue spots  116  upon the final folding operation. In accordance with certain aspects of the invention, timing of the cards  12  and the carriers  14  always remains constant and never out of time (as possible with conventional printing, card placement, and finishing techniques) due to the inherent nature of plow folding of the card panels  112  over onto the carrier panels  114  with an intact backbone or spine (at the fold line  106  therebetween) remaining in place during folding. This process, along with the use of identical and contiguous paper stock blank for cards and carriers, also ensures both circumferential and lateral registration of fine graphics content, color match, and “crossover image” match between the cards  12  and the carriers  14 . 
     As described previously, after completion of the final folding of the card panel  112 , waste materials  110  remain connected to the remainder of the blank  100  with previously folded backbones or spines  119 , which physically connect the card panels  112  to the carrier panels  114 , and, if present, the ties  104  between the waste materials  110  and the partially cut-out cards  102  that were previously glued to the carrier panels  114 . As represented in  FIG. 6D , such a spine  119  created from folded card panels  112  is located at an outer edge of the blank  100 , and may be removed by using the slitting section  224  to cut the spine  119  from the remainder of the card panels  112 . The slitting section  224  may be, but is not limited to, a crush-type rotary slitter wheel which crush/pressure slits against a rotary lower hardened anvil roll surface, or a shear-type rotary slitter which face slits against a side or lower rotating hardened anvil cylinder. Once the spine  119  has been cut, the waste evacuation system  228  may be used to remove the waste materials comprising the spine  119 . 
     As previously noted, the optional waste extraction flap  108  provides an additional region of material (e.g., paper) at what becomes the leading edge of the blank  100  as it reaches the waste separation station  226  in the system  200 . Because the waste extraction flap  108  extends or protrudes beyond the desired finished length of the promotional product  10 , the flap  108  is the first portion of the blank  100  to encounter the waste separation station  226 , and therefore can be an effective aid in removal of the waste material  110  from the blank  100 . The waste separation station  226  may remove the waste material  110  by any means known in the art and rely on any suitable electrical-, mechanical-, pneumatic-, and/or vacuum-based technique. A nonlimiting example of a waste separation station  226  adapted to employ the waste extraction flap  108  to remove the waste material  110  from a blank  100  is represented in  FIG. 12 . The waste separation station  226  is represented as including the aforementioned hook and lift mechanism  240  similar to those typically used in to cross-fold scored carton ends (perpendicular to product travel direction) into the carton center, that is, a folding carton lock bottom. According to aspects of the invention, the hook and lift mechanism  240  is configured to lift and separate the waste materials  110  of card panels  112  by lifting a leading edge of the blank  100 , for example, the waste extraction flap  108 , for removal by the waste evacuation system  228 . As each waste material  110  is removed, its corresponding card  12  remains adhered to its carrier panel  114 . As previously noted, a blank  100  equipped with a waste extraction flap  108  is preferably fed into the system  200  such that, after any flopping of the blank  100 , the waste extraction flap  108  defines the leading edge of the blank  100  in the direction of travel when the blank  100  reaches the waste evacuation system  228 . As such, the hook and lift mechanism  240  is able to first interact with the waste extraction flap  108  to remove the waste material  110  without disturbing the carrier panels  114  or the cards  12  secured thereto. The hook and lift mechanism  240  may be, for example, a timed physical function resulting from the blank  100  triggering an optic or physical sensor to activate a mechanical hook function, or a spring-loaded return hook mechanism which drags the blanks  100  and snags the leading edge of the waste extraction flap  108  as the blanks  100  are conveyed by tapes, rollers, vacuum table belts, or any other drive methods known in the art. 
     Alternatively if the waste extraction flap  108  is not used, any combination of methods known in the art may be used to remove the waste material  110 .  FIG. 11  represents a nonlimiting example comprising one or more vacuum wheels  234  and one or more vacuum tables  236 , for example, a conveyor with a perforated belt through which a vacuum is drawn. In such a configuration, the vacuum table  236  may hold down the carrier panels  114  during removal and air suction extraction of the waste material  110  by the suction wheels  234  and waste evacuation system  228 . 
     Both  FIGS. 11 and 12  further represent the waste separation station  226  as including optional pinching or pressing rollers  238  configured to provide a holding pressure to the partially cut-out cards  102  attached to the carrier panels  114  as the waste material  110  are removed. The pinching/pressing rollers  238  may be adjustable in multiple axes, including a vertical direction (up-down) relative to the vacuum table  236  in order to apply pressure to the partially cut-out cards  102  and the carrier panels  114 , as well as in a horizontal direction (forward-backward) relative to the direction of travel of the blanks  100 . 
     It is also within the scope of the invention that the waste separation station  226  could be limited to using only the vacuum table  236  and/or adjustable guides or fingers (not shown) to hold the carrier panels  114  down while the waste material  110  are removed. Other known nonlimiting methods include cam style rotary, reciprocating type, and/or pivot gates, all of which may function by means of a motion-phased gearbox/belt/pulley or motorized electronic or pneumatic activation devices cued and activated from any type of optic, electronic, or mechanical position sensors through PLC or relay logic activation for all typical methods known for such timing functions. 
     After removal of the waste material  110 , the products  10  will typically comprise one or more cards  12  secured to one of the carrier panels  114 . Any remaining stations of the system  200  may be configured to finish and convert the remainder of the blank  100  from the flat carrier panels  114  into the final promotional product  10 . Nonlimiting examples include folding the carrier panels  114  to produce a multi-page promotional product, spot/line gluing or running perforation to enclose the product  10  to meet postal regulations, additional die cutting processes for features such as windows or sculpted edges, on-serting or label additions, and/or running or pattern perforations to enclose the entire promotional product  10  into a “zip” opening format. For example, step  324  in  FIG. 6F  represents the carrier panels  114  of step  322  ( FIG. 6E ) as being folded along a scored fold line  106  between the panels  114  to form a four-page promotional product  10 . Other foreseeable formats include any conceivable number of lateral or horizontal folds or pagination formats including cross-folding of leading and trailing edge flaps of the blank  100  to create an “iron cross” or an all-sides folding around the card  12 . 
     Processes in accordance with aspects described herein are believed to provide improved economic benefits from improved manufacturing efficiency relative to conventional printing techniques, particularly the web-based printing and finishing techniques represented in  FIGS. 2-4 . Industry trends for high volume web press printed/inline finished promotional products that have cards secured thereto (including the products  10  of  FIGS. 1A-1F ) are such that pressure is building for shorter runs and versioning of high quality value-added products. On-serting and personalization of PVC cards is generally not economically reasonable for direct mail retail advertisers, nor is PVC as environmentally friendly as paper. The production of single- and multi-ply promotional products is one of if not the most popular and exciting web press/inline finishing format in stand-alone high volume retail direct mail today. Improved methods of production are being driven by print advertisers and print buyer demand for lower quantities which are not economically viable from web press/inline finishing operations. The clear trend in virtually all printing disciplines today are declining volumes requested by print buyers for a number of reasons, including but not limited to, increasing competition for budgets from newer electronic media, increasing cost to manufacture traditional web printing, increasing costs of postal delivery, higher accuracy of data collection tracking buying habits, demographics and closed loop feedback all due to VDP and data collection. Print advertisers clearly and accurately define and identify their target buyers specifically using available data which reduces need for flood mailings and increases purchase probability and spend from recipient. Data driven target mailings, specified offers based on recipient history and need to reduce overall costs in advertising budgets directly feed the need for methods such as those described herein. 
     Production costs to operate systems in accordance with aspects of the invention are believed to be much lower compared to conventional web press/inline finishing systems for short to mid-sized run length quantities. In fact, it is generally recognized in the web offset/heat-set direct mail sector that promotional paper card production from web press and finishing specifies low limit manufacture of no less than 200,000 pieces to approach being economically viable due to make-ready time and waste expenditures. Alternative methods for low quantities involve costs to purchase cards separately, separating cards from carriers, costs for additional/multiple printing processes, limited creativity in card placement or design, additional read/write VDP/encoding, slower production output speeds, camera/verification systems, costs, etc., making those alternatives very costly as well. Processes in accordance with preferred aspects of the invention are believed to provide a major economic advantage over conventional printing and card-finishing production methods for printing quantities as low as about 5,000 to 10,000 pieces, with the greatest economic benefits believed to be achieved in printing quantities between about 20,000 to 200,000 pieces. 
     While the invention has been described in terms of specific embodiments, it is apparent that other forms could be adopted by one skilled in the art. For example, the physical configuration of products produced by processes described herein could differ from the products  10  depicted in the drawings, and the physical configurations of the system  200  and its stations and units could differ from those shown in the drawings, functionally equivalent equipment could be substituted for the units and equipment described, and materials and processes other than those noted could be used. Therefore, the scope of the invention is to be limited only by the following claims.