System for assembling cards in trays

A system for assembling cards in trays includes a pack stacker that stacks cards, a pack separator, a tray for receiving cards, and a processor. The processor is programmed to determine a number of cards in the tray, operate the pack stacker to assemble a plurality of cards into a stack, determine whether the plurality of cards can be accommodated in the tray together with the number of cards and, if so, transfer the stack to the tray. The processor is also programmed to operate the pack separator to separate the stack of cards into a sub-stack if the processor determines that the plurality of cards cannot be accommodated in the tray together with the number of cards wherein the sub-stack has less than the plurality of cards and transfer the sub-stack to the tray.