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

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

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

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

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

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

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

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.

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

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 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 30 60 24 33 70 28 64 75 41 68 80 31 44 73 90 82 100 56 91 110 128 116

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.

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

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

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

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

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

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

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

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

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 http://pe.usps.com/FRN/Booklets.pdf EFFECTIVE DATE: September 8, 2009

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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