1. BOOKLETS New Requirements Automation & Machinable Letter Prices
for
Automation & Machinable Letter Prices

2. Overview – what led us here?
R2006 price increase for flat-size catalogs prompted shift to letter-size catalogs (e.g. “slim jims”)
Letters process on automation equipment at the rate of 10 pieces per second
Booklets (“slim jim” letter and digest-size) do not behave like enveloped pieces:
Tend to jam equipment
Can become significantly damaged
Tabbing methods often insufficient
Pieces frequently moved to flat-sorters and manual operations:
Reduce jam and damage rates
Greater processing and delivery costs

3. Overview – how did we react?
Extensive testing to determine which characteristics and combinations enable processing on the DBCSs (primary letter sorting machines):
Phase 1 – controlled test in fall 2007
Mailer-supplied pieces – collaborated with industry in summer/fall 2008
Phase 2 – controlled test through fall 2008
Seven Characteristics
Binding
Cover Stock
Size
Tab locale, style, strength
Thickness

4. Test Results, Mailer-Supplied Pieces
Mailpiece Damage – Tab Tear

5. Mailpiece Damage – Tab and Cover Tear
Test Results, Phase 2
Mailpiece Damage – Tab and Cover Tear

6. Test Results TABS PAPER SIZE
Three tabs performed better than two tabs on all styles
Large tabs (at least 1.5 inches) performed better than small tabs
Nonperforated tabs sealed better than perforated tabs, which tended to burst
PAPER
50-pound paper covers processed acceptably on some
smaller and lighter pieces; at least 60-pound paper needed
on most pieces
SIZE
Pieces were problematic over 10.5 inches long or when weighing at or near 3 ounces

7. Booklets Mailpiece Design
New standards for letter-sized booklets Federal Register published on April 15, 2009
General overview:
Define standards for design, preparation, and sealing of machinable and automation letter-size booklets
Describe minimum requirements and provide recommendations based on wide variety of test observations and several years of analysis
Provide illustrations of new requirements
Minimize mailpiece damage and maximize efficient processing
Effective September 8, 2009

8. Booklets Mailpiece Design
Booklets definition and illustrations:
Multiple sheets of paper bound together on one edge to form a spine; may be perfect-bound or permanently fastened with staples or another method that creates a uniformly thick mailpiece.
Larger booklets may be folded to letter-size so long as final mailpiece remains uniformly thick.
Spiral bindings are not machinable and do not qualify for automation prices.

9. Booklets Mailpiece Design – Physical Standards
Dimensions and weight requirements for automation and machinable letter prices
Booklets:
Height – 3.5 inches to 6 inches
Length – 5 inches to 10.5 inches*
Thickness – inch to 0.25 inches
Aspect ratio – within 1.3 to 2.5
Maximum weight – 3 ounces
*Note: some booklet designs have shorter maximum lengths

10. Booklets Mailpiece Design – Paper Requirements
Generally booklet covers must be made with a minimum paper basis weight of 60-pounds book-grade or equivalent.
Minimum basis weights are higher for some designs
DMM 201 Exhibit lists minimum paper weights by design
DMM minimum paper basis weights are based on book-grade
NOTE:
Paper basis weight is based on the weight of 500 sheets of:
25 x 38 inch sheets of book-grade paper,
17 x 22 inch bond-grade paper,
20 x 26 inch sheets of cover-grade paper,
24 x 36 inch sheets of newsprint.
For example, if 500 sheets of book-grade paper weigh 39 pounds, the paper is considered 39-pound book paper.
Book Wt.
Bond Wt.
Cover Wt.
Newsprint Wt. 39 15 21 35 40 16 22 36 50 20 27 45 55 30 60 24 33 70 28 64 75 41 68 80 31 44 73 90 82
100 56 91
110
128
116

11. Booklets Mailpiece Design – Paper Requirements
NOTE:
Paper basis weight is based on the weight of 500 sheets of:
25 x 38 inch sheets of book-grade paper,
17 x 22 inch bond-grade paper,
20 x 26 inch sheets of cover-grade paper,
24 x 36 inch sheets of newsprint.
For example, if 500 sheets of book-grade paper weigh 39 pounds, the paper is considered 39-pound book paper.
Book Wt.
Bond Wt.
Cover Wt.
Newsprint Wt. 39 15 21 35 40 16 22 36 50 20 27 45 55 30 60 24 33 70 28 64 75 41 68 80 31 44 73 90 82
100 56 91
110
128
116
Paper Conversion Example:
Mailing Standard: Minimum Paper Weight is 60 lbs
If the mailpiece cover is 55 lb newsprint that equals the minimum paper weight of 60 lbs book-grade.
If the mailpiece cover is 50 lb newsprint that does not equal the minimum paper weight of 60 lbs book-grade.

12. Booklets Mailpiece Design – Design and Sealing
Booklets may be designed with the spine or final fold at the bottom or on the leading edge.
↑ Spine
← Spine

13. Booklets Mailpiece Design – Closure Method
Tabs:
Three 1.5-inch tabs required on all booklets
Non-perforated tabs required on all pieces
Recommend white paper tabs
Recommend 2-inch tabs on booklets over 2.5 ounces
1.5” - 2” width

14. Booklets Mailpiece Design – Closure Method
Glue Spot:
May be used in lieu of tabs
Must be placed within ¾” of the open edges

15. Booklets Mailpiece Design – Closure Method
Glue Line:
May be used as cover-to-cover seals
Must be placed along the entire edge and no more than ¾” from the open ends

16. Booklets Mailpiece Design
Simple-Spine Booklet:
Spine on bottom (longer) edge
Place two tabs on leading edge and one on trailing edge:
Position lower leading tab 0.5 inch from bottom edge
Position upper tabs 1 inch from top edge
May use 50-pound – 5” to 9”; 60-pound paper recommended
Must use 60-pound on pieces over 9 inches long

17. Booklets Mailpiece Design
Folded Booklet (“Quarter-Fold”):
Final fold on bottom (longer) edge; spine folded on leading edge
Place two tabs on leading edge and one on trailing edge:
Position lower leading tab 0.5 inch from bottom edge
Position upper tabs 1 inch from top edge
May use 40-pound; 50-pound paper recommended

18. Booklets Mailpiece Design
Spine-Right Booklet (Oblong):
Spine on leading (shorter) edge
Place two tabs on top edge and one on trailing edge:
Position top tabs no more than 1 inch from left and right edge
Position trailing tab no lower than the middle
May use 60-pound; 70-pound paper recommended
Must use 70-pound on pieces over 9 inches long

19. Booklets Mailpiece Design
Perfect Bound
Spine on bottom (longer) edge; non-perforated inner flap on top (upper edge)
Perfect bound or saddle stitched with a continuous glue line along flap preferred, minimum 1” glue spots acceptable if placed within ¾” of right and left edges:
Must use 80-pound paper

20. Booklets Mailpiece Design
Reminder!
Booklets Mailpiece Design
New Standards for Booklet
Automation and Machinable
Letter Prices
Federal Register – final rule
Vol. 74, No. 71 / Wednesday, April 15, 2009 / Rules and Regulations
EFFECTIVE DATE: September 8, 2009

21. What about Folded Self-Mailers?
Postponed proposed Folded Self-Mailer rule
Established advisory team through MTAC leadership for further collaboration on mailpiece evaluation and testing
Utilize mailer-supplied test material, in addition to USPS controlled test designs
Target test completion by August 2009
Proposed rule in Fall 2009

22. Questions