New Tabbing Requirements for Booklets Receiving

Automation & Machinable Letter Prices

BOOKLET

Pam KellerMailpiece Design Analyst

Western PA District

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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

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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

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Test Results, Mailer-Supplied Pieces

Mailpiece Damage – Tab Tear

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Test Results, Phase 2

Mailpiece Damage – Tab and Cover Tear

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What Did We Learn

TABSThree 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

PAPER50-pound paper covers processed acceptably on some smaller and lighter pieces; at least 60-pound paper needed on most pieces

SIZEPieces were problematic over 10.5 inches long or when weighing at or near 3 ounces

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How We Implemented the Change

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

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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

(saddle stitched) 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.

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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 – 0.009 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

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Booklets Mailpiece Design –Paper Requirements

Paper:

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 3.15.4 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 22 30 50

60 24 33 55

70 28 40 64

75 30 41 68

80 31 44 73

90 36 50 82

100 40 56 91

110 44 60 100

128 50 70 116

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Booklets Mailpiece Design –Paper Requirements

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.

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 22 30 50

60 24 33 55

70 28 40 64

75 30 41 68

80 31 44 73

90 36 50 82

100 40 56 91

110 44 60 100

128 50 70 116

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Booklets may be designed with the spine

or final fold at the bottom or on the leading

edge.

Booklets Mailpiece Design –Design and Sealing

↑ Spine

← Spine

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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

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Glue Spot:

– May be used in lieu of tabs

– Must be placed within ¾” of the open

edges

– Must be at least 1” in diameter

Booklets Mailpiece Design – Closure Method

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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 end

Booklets Mailpiece Design – Closure Method

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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

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Booklets Mailpiece Design

Simple Spine - Wallet Style Saddle-stitched spine (two or more staples) on the bottom (longer) edge. 4" height only. Maximum Weight 2.5 ounces. 5.2'' to 8'' long 60-pound for cover and pages 70-pound cover with 50-pound pages Two 1.5'' or 2'' non-perforated tabs One tab on leading edge and one tab on trailing edge.

Booklets up to 2 ounces: 1.5" tabs ---1-1/4" from bottom edge

Over 2 ounces up to 2.5 ounces: 2" tabs -- 3/4" from bottom edge ±1/8" vertical tolerance for tab placement for both tab sizes

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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

Folded BookletTwo tabs on leading edge; one tab on trailing edge. Position lower leading tab 0.5 inch from the bottom edge. Position upper tabs 1 inch from the top edge.

Three 1.5” non- perforated tabs

40-pound 5” to 10.5”

long

Final fold on the bottom (longer) edge, with the folded spine on the leading or trailing (shorter) edge

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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

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Booklets Mailpiece Design

Perfect BoundSpine 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

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Booklets Mailpiece Design

Perfect BoundPerfect bound or saddle stitched with a continuous glue line along the top open edge of the cover preferred, minimum 1” glue spots acceptable if placed within ¾” of right and left edges:

Must use 80-pound paper

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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 Fall 2009

Proposed rule in Winter 2009 -2010

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WHO ARE MY RESOURCES?

• Mailing Requirements

• Business Mail Entry Units

• Mailpiece Design Analyst

• Mailing Standards Specialist

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THE END RIGHT ON TARGET

U.S.P.S.

QUESTIONS??