A collator is a machine that automatically sorts paper, card, film, or packaging. It arranges these materials in the correct order for binding, mailing, or shipping. In US print and packaging facilities, collators boost output, ensure accuracy, and lessen the need for manual labor.
Manual collation of hundreds of sheets or components often results in errors, waste, and missed deadlines. Automation resolves these risks by ensuring consistent accuracy at scale. According to IBISWorld’s 2025 industry analysis, there are 48,740 businesses in the Printing industry in the United States. This is an industry that has grown at a CAGR of 0.3% between 2020 and 2025. This significant presence reflects a clear need for efficient collation solutions. The printing industry in the United States is evolving due to technological advances. We have installed more than 100 machines nationwide, backed by 30 years of engineering expertise and a service agent based in Missouri.
Our systems work with various materials, from thin plastics to thick board. They cater to needs in print, packaging, and security card production.
A collator operates through a structured sequence designed for accuracy and consistency. Each machine is built with multiple input trays, where different sheets or components are loaded. Feeders then draw one sheet at a time into the collating station, where the materials are arranged in the programmed order. The complete sets are transferred to the output stacker, ready for binding, boxing, or distribution.
Core components of a collator include:
More US facilities are recognizing the importance of automation in manufacturing processes. According to the U.S. Census Bureau’s Survey of Manufacturing Technology, factories that use more automation generally have lower labor costs and invest more capital. As a result, workers earn higher wages due to increased productivity.
This data reinforces why collation automation delivers measurable returns on investment. Recent data from the Bureau of Labor Statistics shows that U.S. manufacturing productivity rose by 1.8% in the second quarter of 2024. These productivity gains translate directly into competitive advantages for those embracing collation technology. Our engineers showcase this process using filmed trials on client stock. Buyers can see clear evidence of performance before delivery. A library of collator videos is also available, showing how our machines handle a wide range of materials.
Collators are integral to industries where accuracy and efficiency are critical. Commercial print shops create brochures, reports, and booklets. These items are prepared for binding or distribution right away. This helps facilities meet deadlines without the delays associated with manual collation.
In packaging settings, collators arrange product inserts, promotional sheets, and multi-part packaging. After that, these items go to boxing or palletizing. Direct mail providers use collators to put together letters, forms, and marketing packs. This helps create complete, well-organized sets. It ensures that high-volume campaigns are delivered on time and without mistakes. The demand for automated solutions in these sectors reflects broader market trends. Network Distribution’s 2024 Industrial Packaging Insights report shows that the industrial packaging market was worth $63.3 billion in 2024. It is projected to grow nearly 5% each year, reaching $80.9 billion by 2028. This growth comes from higher demand in many sectors that need careful material handling and assembly.
The U.S. packaging automation market specifically was valued at nearly $22.82 billion in 2023 and is projected to grow at a CAGR of 5.7% between 2024 and 2032. These statistics indicate that collation equipment supports thriving industries. Investing in automation is, therefore, a smart move. We have also created systems for specific uses, such as security and ID card production. In these cases, precise layering is needed before bonding or finishing. By automating these processes, US businesses cut waste, boost throughput, and keep quality steady in every project. Explore more insights on our blog covering the role of automation in production workflows.
Collators create measurable advantages for US businesses by combining speed, reliability, and flexibility. Three benefits stand out:
Automated collation increases throughput by eliminating manual sorting. Research from the US Census Bureau shows that productivity growth in printing and similar activities depends heavily on automation and digital investment. This reduces turnaround times in high-volume facilities.
Integrated detection systems monitor every sheet, reducing the risk of missing or duplicate pages. This alone helps safeguard the brand’s reputation. It also prevents costly reprints, particularly in industries where error-free assembly is essential.
Collators adapt to a range of materials and production runs, from small batches to large industrial orders. Tailored builds and specialized applications enhance scalability. This ensures each machine is aligned with the client’s workflow and long-term growth plans.
For over 30 years, we have offered collating systems that combine robust engineering with adaptable design. We have over 100 machines across the country and a service agent in Missouri. This means you get reliable equipment and local support.
What sets Col-Tec USA apart is our commitment to transparency and client assurance:
These measures give businesses confidence. This way, they ensure each machine is tested, supported, and designed for long-term efficiency in production lines.
Collators offer clear benefits for US print, packaging, and mailing facilities. They boost accuracy, increase throughput, and support scalable production. Automated precision replaces manual sorting, helping facilities meet deadlines and reduce costly errors
Col-Tec US combines over 30 years of engineering expertise with a nationwide service network and more than 100 machines installed. Our systems are well-tested, documented, and supported to ensure long-term reliability. The right collator can strengthen your business by improving accuracy, efficiency, and consistency.
Call 001 314 537 1525, request a consultation or arrange a filmed demonstration of your own stock.
There is a Col-Tec collator for every application and budget.
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