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BOOKLETSNew Requirements

for

Automation & Machinable Letter Prices

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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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Test Results

TABS 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

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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

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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 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

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 ends

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

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

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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 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

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Booklets Mailpiece Design

New Standards for Booklet

Automation and Machinable

Letter Prices

Federal Register – final ruleVol. 74, No. 71 / Wednesday, April 15, 2009 / Rules and Regulations

http://pe.usps.com/FRN/Booklets.pdf

EFFECTIVE DATE: September 8, 2009

Reminder!

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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 August 2009

Proposed rule in Fall 2009

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Questions