November 2018 i
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Online Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Postal Groups, Activities, and People . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
National Postal Forum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Postal Customer Councils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Postal Service Seminars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Postal Service Specialists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Non-USPS Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Letter-size Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-1 Types of Letter-size Mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2 Physical Standards for Letters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2.1 Dimensional Standards for Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2.2 Length and Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-2.3 Aspect Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-3 Address Placement for Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-3.1 Nonmailable Placement of the Delivery Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-3.2 Proper Delivery Address Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-3.3 Proper Return Delivery Address Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Machinable and Automation Letters and Cards . . . . . . . . . . . . . . . . . . . . . . . 11
2-1 Physical Standards for Machinable and Automation Letters and Cards. . . . . . . . . . . . . . . . 11
2-1.1 Basic Standards for Automation Letters and Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-1.2 Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-1.3 Dimensions and Shape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-1.4 Maximum Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-1.5 Heavy Letter Mail (More Than 3 Ounces) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-1.6 Postcard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-1.7 Aspect Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-1.8 Wraps and Closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-1.9 Staples and Saddle Stitching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-1.10Rigid and Odd-shaped Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Designing Letter and Reply Mail
ii Publication 25
2-2 Flexibility Standards for Automation Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-2.1 Machinability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-2.2 USPS Services for Flexibility Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-3 Attachments on Letter-size Mailpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-3.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-3.2 Pressure-sensitive Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-3.3 “Sandwich” Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-3.4 Letter-size Piece With Attached Release Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-3.5 Standards for Release Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-3.6 Letter-size Pieces With Perforated Pockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-3.7 Standards for Perforated Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Nonmachinable Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-1 Criteria for Nonmachinable Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-2 Additional Criteria for First-Class Mail Nonmachinable Letters. . . . . . . . . . . . . . . . . . . . . . . 19
3-3 Additional Criteria for USPS Marketing Mail Nonmachinable Letters . . . . . . . . . . . . . . . . . . 19
3-4 Additional Criteria for Periodicals Nonmachinable Letters . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-5 Priority Mail Express and Priority Mail Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-6 Nonmachinable Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-7 Odd-shaped Items in Paper Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-8 Handling, Content, and Extra Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-9 Window Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-10 Green Diamond Border Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-2 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-3 Physical Standards for Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-4 General Booklet Design and Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-5 Tabs, Tape, and Glue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-6 Simple Spine Booklets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-6.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-6.2 Simple Spine Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-6.3 Lightweight Simple Spine Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-6.4 Mid-weight Simple Spine Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-6.5 Heavy-weight Simple Spine Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-7 Wallet-style Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4-8 Oblong Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4-9 Quarter-folded Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4-10 Folded Self-mailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Contents
November 2018 iii
5 Letter-size Pieces Containing Discs (CDs or DVDs). . . . . . . . . . . . . . . . . . . . 33
5-1 Basic Standards for Discs in Letter-size Mailpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-2 Disc Size and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-3 Dimensions and Shape Standards for Automation-compatible Enveloped Letters C
ontaining Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-4 Dimensions and Shape Standards for Automation-compatible (Unenveloped) Disc
Carriers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-5 Unacceptable Characteristics for Automation-compatible Letter-size Pieces with
Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Business Reply Mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6-3 Ink/Paper Colors and Type Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 Courtesy Reply Mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-2 Barcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7-4 Ink/Paper Colors and Type Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8 Meter and PC Postage Reply Mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-2 Barcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8-4 Ink/Paper Colors and Type Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9 Permit Reply Mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9-2 Using Company Permit Reply Mail Imprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10 Facing Identification Mark (FIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-1 Description and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-1.2 Using FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-1.3 Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-2 FIM Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-3 Print Reflectance Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-4 FIM Positives and Barcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-5 Obtaining FIMs, Barcodes, and ZIP Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-6 Importance of Correct Barcodes and FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Designing Letter and Reply Mail
iv Publication 25
11 Ink/Paper Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11-2 Ink/Paper Colors and Type Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11-3 Paper Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11-4 Reflectance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11-4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11-4.2 Print Reflectance Difference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11-4.3 Print Contrast Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11-5 Address Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11-6 Intelligent Mail Barcodes, Delivery Point Barcodes, and FIM Measurements . . . . . . . . . . . . 62
12 Barcoding Software and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12-1 CASS and MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12-2 PAVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
November 2018 v
List of Exhibits
Exhibit 1-2.1
Minimum Letter Dimensions, Mailpieces 1/4" Thick or Less . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exhibit 1-2.3
Examples of Aspect Ratio (Not Drawn to Scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhibit 1-3.2
OCR Read Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhibit 2-1.2
Paper Basis Weight Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhibit 4-5f
Glue Spot Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Exhibit 4-5g
Glue Line Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Exhibit 4-6.2
Simple Spine Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exhibit 4-6.3
Lightweight Simple Spine Booklets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Exhibit 4-6.4
Mid-weight Simple Spine Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exhibit 4-6.5
Heavy-weight Simple Spine Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Exhibit 4-7
Wallet-style Booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exhibit 4-8
Oblong Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Exhibit 4-9
Quarter-folded Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Exhibit 6-1a
Business Reply Mail Layout Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Exhibit 6-1b
Business Reply Mail Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Exhibit 6-2
Dimensions for Postcards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Exhibit 7-1a
Courtesy Reply Mail Layout Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exhibit 7-1b
Courtesy Reply Mail Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Exhibit 8-1a
Meter or PC Postage Reply Mail Layout Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Designing Letter and Reply Mail
vi Publication 25
Exhibit 8-1b
Meter or PC Postage Reply Mail Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Exhibit 9-1
Permit Reply Mail Format Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Exhibit 10-1
FIM Patterns (not drawn to scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Exhibit 10-2
FIM Layout Guidelines (not drawn to scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Exhibit 11-4.1a
Decimal and Fractional Equivalents — Fractions Divisible by 32, 16, 8, and 4 . . . . . . . . . . . . . . . . . 60
Exhibit 11-4.1b
Decimal and Fractional Equivalents — Fractions Divisible by 25 and 5 . . . . . . . . . . . . . . . . . . . . . . . 61
The following trademarks appear in the handbook and are among the many
tra
d
emarks owned by the
United States Postal
Servi
c
e
®
:
Business Reply Mail
®
, CASS™, CASS Certified™, Certified Mail
®
, Courtesy Reply Mail™, DMM
®
,
FASTforward
®
, First-Class Mail
®
, IMb
®
, IMM
®
, Intelligent Mail
®
, MASS™, Media Mail
®
,
NCOA
Link®
, PAVE™, PC Postage
®
, Post Office™, Postal Explorer
®
, Postal Service™,
PostalOne!
®
, Priority Mail
®
, Priority Mail Express
®
, Qualified Business Reply Mail™ (QBRM™),
Registered Mail®, United States Postal Service
®
, USPS®, USPS Marketing Mail®, ZIP™, ZIP+4
®
,
and ZIP Code™.
This is not a comprehensive list of all Postal Service™
t
r
a
d
emarks.
November 2018 1
Introduction
Purpose
The Postal Service has five mail processing categories for mailpieces:
a. Letters.
b. Flats.
c. Machinable parcels.
d. Irregular parcels.
e. Nonmachinable parcels.
The Postal Service assigns each mailpiece to one of these mail processing
categories based on the physical dimensions and characteristics of the
mailpiece using the longest dimension as the length, regardless of the
placement or orientation of the delivery address on the piece. USPS
standards exist so that mailers can design mailpieces that the Postal Service
can effectively process on our sorting machines.
This publication is intended to provide guidance for mailers who design
letter-size mailpieces, and especially automation-compatible designs.
Printers, graphic artists, forms designers, envelope manufacturers, and
computer programmers can find useful information from basic addressing to
technical specifications.
This publication is based on Mailing Standards of the United States Postal
Service, Domestic Mail Manual (DMM), which is the final authority on
domestic mailing standards. The Postal Service routinely updates the DMM.
The DMM contains the standards governing domestic mailing services and is
available on the Postal Explorer Web site at pe.usps.com. If you are not
familiar with the organization and numbering system in the DMM, a tutorial is
available on the Postal Explorer Web site.
Notice 123, Price List, is the published list of USPS prices and is available on
the Postal Explorer Web site at pe.usps.com/
.
Some of the information in this publication is technical. For additional
assistance, contact your local Post Office.
Designing Letter and Reply Mail
2 Publication 25
More Information
Online Resources
Addressing
Publication 28, Postal Addressing Standards, describes addressing for the
best service. It is available online at https://pe.usps.com/cpim/ftp/pubs/
Pub28/pub28.pdf.
Addressing Software
For information on addressing products and services, go to the PostalPro
Web site at Postalpro.usps.com or contact the National Customer Support
Center (NCSC) at 800-238-3150.
Domestic Mail
The DMM is the Postal Service manual that contains the mailing standards
governing domestic mail services, descriptions of mail classes, the
conditions governing their use, and eligibility. The DMM is updated routinely
and is available free of charge on the Postal Explorer Web site at
pe.usps.com.
The DMM provides further information on many of the topics discussed in
this publication, as follows:
a. See DMM 201.3 for information about machinable and automation
letters and cards (discussed in chapter 2).
b. See DMM 201.2 for information about physical standards for
nonmachinable letters (discussed in chapter 3).
c. See DMM 201. 3 for information about booklets (discussed in
chapter 4).
d. See DMM 201.3 for information about letter-size pieces containing
discs (CDs or DVDs) (discussed in chapter 5).
e. See DMM 505.1 for information about Business Reply Mail items
(discussed in chapter 6).
f. See DMM 505.2 for information about Courtesy Reply Mail items
(discussed in chapter 7).
g. See DMM 505.2 for information about meter and PC Postage reply mail
(discussed in chapter 8).
h. See DMM 505.2 for information about permit reply mail (discussed in
chapter 9).
i. See DMM 202.8 for information about facing identification marks
(FIMs) (discussed in chapter 10).
Latest News
The DMM Advisory keeps you informed about mailing issues that are
important to your business. You can find updates to our mailing standards
and prices, information about our Web tools, and helpful reminders about
mailing issues. To subscribe to the DMM Advisory or to send comments and
Introduction
November 2018 3
suggestions, email us at [email protected]. To subscribe, simply
indicate “subscribe” in the subject line.
The Postal Bulletin is the official source for updates to policies, procedures,
forms, and operational information about the Postal Service. The Postal
Service publishes an edition every 2 weeks, and both current and archived
editions are available through the Postal Explorer Web site at pe.usps.com;
under “Publications,” click on Postal Bulletin. To subscribe, submit your
credit card order by telephone by calling 800-STAMP-24.
Postal Explorer
The Postal Explorer Web site at pe.usps.com is an online library of postal
information designed for business mailers. It puts a wealth of postal
information at your fingertips in an easy-to-use format. The powerful search
feature lets you quickly find information in a single publication or across a
range of publications. You can view a publication by clicking on the
publication title.
Also available on the Postal Explorer Web site are the following items:
a. Mailing Standards of the United States Postal Service, International
Mail Manual (IMM).
b. Domestic, international, and business postage calculators.
c. ZIP Code Lookup.
d. Zone Chats.
e. Postage statements.
f. Templates for designing Business Reply Mail (BRM) and Courtesy
Reply Mail (CRM) at https://pe.usps.com/MailpieceDesign/
Index?ViewName=ABRMIntroduction.
g. Artwork for creating BRM at https://pe.usps.com/MailpieceDesign/
Index?ViewName=ABRMIntroduction.
h. Other Postal Service publications.
Prices
Notice 123, Price List, provides retail and commercial prices for domestic
and international services in a concise and accessible format. Available on
the Postal Explorer Web site at pe.usps.com
. The current edition of Notice
123 is available on the Postal Explorer Home Page.
Quick Service Guides
Each Quick Service Guide provides a summary of the applicable standards in
the DMM. The Quick Service Guides summarize the mailing standards for a
particular class of mail or preparation option, and they provide links to the
DMM. The Quick Service Guides are available on the Postal Explorer Home
Page, and topics include the following:
a. Retail letters, flats, and parcels.
b. Commercial letters and postcards.
c. Commercial flats.
d. Commercial parcels.
e. Additional services.
Designing Letter and Reply Mail
4 Publication 25
f. Basic standards for all mailing services.
g. Special standards.
h. Reference.
Training
“Mail Design Professional” is a self-study course that helps you to design
mailpieces with an emphasis on automated mail processing. The course
provides information on the classes of mail, mail processing categories
(shapes), and basic presort. The course is recommended for all mailers and
is available on the Business Mail Academy Web site at http://nced.com/bma
;
under “Business Customer Courses,” click on Start Online Course.
Postal Groups, Activities, and People
National Postal Forum
The National Postal Forum (NPF) is an educational and trade show event for
the mailing industry held annually at different locations throughout the nation.
For more information, visit the NPF Web site at npf.org.
Postal Customer Councils
Most areas have a local Postal Customer Council (PCC), which can give you
tips from experienced mailers who have successfully developed business
mailing programs. PCCs have general meetings to discuss Postal Service
issues. To find a PCC near you, go to http://about.usps.com/postal-
customer-council/pcc-locator.htm.
Postal Service Seminars
The Postal Service offers seminars on direct mail at selected sites around
the country. Your local business mail entry office can tell you when
seminars are offered in your area. To find your local business mail entry
office, go to
https://postalpro.usps.com/node/1623.
Postal Service Specialists
The following USPS personnel can provide assistance in many areas:
a. Postmasters: Your local postmaster can help you with many basic
questions about preparing your presorted mailing. However, there are
other postal specialists to help you with more complex technical
issues, including the others listed in this section.
b. Business Service Network representative: The Business Service
Network (BSN) is a nationwide network dedicated to providing service
support to the largest mailers of the U.S. Postal Service. To find your
local BSN representative, go to https://ribbs.usps.gov/locators/find-
bsn.cfm.
Introduction
November 2018 5
c. Mailpiece Design Analysts: Mailpiece Design Analysts (MDAs)
specialize in the design of mail for effective processing on USPS
automated equipment, and they are resources for Intelligent Mail
information. To find an MDA, go to pe.usps.com; click on Business
Solutions; and click on Mailpiece Design Analyst.
d. Mailing Standards Specialists: Located in various districts of the U.S.
Postal Service and supported by the business mail entry manager,
these specialists are excellent resources for advice on DMM
standards.
e. Business Mail Entry Managers: Located in districts and supported by
the Pricing and Classification Service Center (PCSC), these managers
are experts on the regulations described in the DMM and can give you
advice if you want to try something new. To find your district business
mail entry office, go to pe.usps.com; click on Business Solutions; and
click on Business Mail Entry Locator.
Non-USPS Resources
Some mail-related services are handled by private companies rather than by
the Postal Service, including the following:
a. Mailing lists: To purchase or rent a mailing list, search for “mailing list”
on the Internet.
b. Postage evidencing systems: Postage meters and PC Postage
products are collectively identified as “postage evidencing systems” —
search for this term on the Internet.
c. Vendors: Product categories include postage meters and PC Postage
products. Additional information on product categories and authorized
providers is available online at https://www.usps.com/business/
postage-options.htm. To lease a postage meter, search for “postage
meter” on the Internet.
d. Presort service bureaus: To find a presort service bureau, search for
“presort service” on the Internet.
Designing Letter and Reply Mail
6 Publication 25
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November 2018 7
1 Letter-size Basics
1-1 Types of Letter-size Mail
In addition to determining the mail processing category using the weight and
shape of the mailpiece, the Postal Service also classifies mailpieces by the
way they are prepared. The Postal Service bases these classifications on
how efficiently Postal Service equipment can process your mailpieces, which
fall under one of the following three categories:
a. “Automation” letter-size mailpieces are machinable and contain correct
delivery point information in the imprinted Intelligent Mail barcodes.
Letters and cards can receive postage discounts if they meet
automation standards.
b. “Machinable” mailpieces can be sorted on Postal Service processing
equipment. Sorting mail on automated equipment is more efficient than
manual processing, so properly prepared machinable pieces can
qualify for lower prices — but not for Automation prices because
achinable pieces do not have a qualifying barcode.
c. “Nonmachinable” mailpieces cannot be processed by Postal Service
equipment. Because nonmachinable pieces must be sorted manually,
higher postage prices might apply because of the additional postal
handling needed.
1-2 Physical Standards for Letters
1-2.1 Dimensional Standards for Letters
The Postal Service defines letter-size mail as follows:
a. Not less than 5" long, 3-1/2" high, or 0.007" thick. See Exhibit 1-2.1
.
b. Not more than 11-1/2" long, 6-1/8" high, or 1/4" thick.
c. Rectangular, with four square corners and parallel opposite sides.
Letter-size, card-type mailpieces made of cardstock may have finished
corners that do not exceed a radius of 1/8".
d. Having the following maximum weights:
(1) Retail Letters: 3.5 ounces. First-Class Mail letter-size pieces over
3.5 ounces are charged at the large envelope (flat) prices.
(2) Machinable and Automation Letters and Cards:
(a) Automation enveloped letters and cards: 3.5 ounces.
1-2.2 Designing Letter and Reply Mail
8 Publication 25
(b) Machinable enveloped letters and cards: 3.5 ounces.
(c) Booklets and folded self-mailers: 3 ounces.
Exhibit 1-2.1
Minimum Letter Dimensions, Mailpieces 1/4" Thick or Less
1-2.2 Length and Height
To determine the mailability or machinability of a letter-size mailpiece, the
length is the dimension parallel to the delivery address as read; the height is
the dimension perpendicular to the length. Because the location of the
delivery address on a letter-size mailpiece determines which dimensions are
the length and height, the placement of the address may make a piece
nonmailable or nonmachinable.
Note: When listing dimensions, the normal practice is to list length
first — e.g., a dimension listed as 4" by 6" usually indicates that the
length is 4".
1-2.3 Aspect Ratio
The aspect ratio is the length of the mailpiece divided by the height. For a
letter-size piece to be machinable, this number must be between 1.3 and 2.5,
inclusive. This ensures that the mailpiece travels properly on USPS
machinery. Pieces that are too tall relative to their length tend to tumble
during processing. See Exhibit 1-2.3
.
Letter-size Basics 1-3.1
November 2018 9
Exhibit 1-2.3
Examples of Aspect Ratio (Not Drawn to Scale)
1-3 Address Placement for Letters
1-3.1 Nonmailable Placement of the Delivery Address
The placement of the delivery address on a letter-size mailpiece may make a
piece nonmailable or nonmachinable.
A letter-size mailpiece is nonmailable if any of the following circumstances
apply:
a. The length (the dimension parallel to the delivery address) is less
than 5".
Example: For a letter-size piece that is 4" by 6" (which indicates
that the delivery address is parallel to the 4" dimension, which
means that its length is 4"), its 4" length is less than the minimum
required length of 5". This piece is nonmailable.
b. The height (the dimension perpendicular to the length) is less than
3 1/2".
Example: For a mailpiece (including a letter-size mailpiece) that is
6" by 3" (which indicates that the delivery address is parallel to the
6" dimension, which means that its length is 6" and its height is 3"),
its 3" height is less than the minimum required height of 3 1/2".
This piece is nonmailable.
c. The aspect ratio (length divided by height) is not between 1.3 and 2.5,
inclusive.
Example: For a letter-size piece that is 5" by 8" (which indicates
that the delivery address is parallel to the 5" dimension, which
means that its length is 5" and its height is 8"), its aspect ratio (5"
length divided by 8" height) is 0.625, which is not between 1.3 and
2.5, so it is mailable but as a nonmachinable letter.
Designing Letter and Reply Mail
10 Publication 25
This page intentionally left blank
1-3.2 Proper Delivery Address Placement
On a letter-size piece, the entire delivery address should be within the
Optical Character Reader (OCR) read area, which is defined as follows:
a. Left: 1/2" from the left edge of the piece.
b. Right: 1/2" from the right edge of the piece. (The Postal Service
recommends 3/4" because of lead edge fold over.)
c. Top: 2-3/4" from the bottom edge of the piece.
d. Bottom: 5/8" from the bottom edge of the piece.
See Exhibit 1-3.2
.
Having the delivery address within the OCR read area gives the Postal
Service the best opportunity to read the address and to apply a correct
routing barcode to the mailpiece.
Exhibit 1-3.2
OCR Read Area
1-3.3 Proper Return Delivery Address Placement
The return address tells the Postal Service where the sender of a mailpiece
wants it returned if the Postal Service cannot deliver it. Place the return
address in the upper-left corner of the address side of the mailpiece or the
upper-left corner of the addressing area. The requirements for a letter-size
piece are as follows:
a. Left: 1/2" from left edge of the piece.
b. Top: 6" from the bottom edge of the piece.
November 2018 11
2 Machinable and Automation Letters
and Cards
2-1 Physical Standards for Machinable and Automation
Letters and Cards
2-1.1 Basic Standards for Automation Letters and Cards
Letters and cards claimed at any machinable, automation, or at USPS
Marketing Mail carrier route price, must meet the standards in the DMM.
Unless prepared as a folded self-mailer, booklet, or postcard, each
machinable or automation letter must meet one of the following
characteristics:
a. Be a sealed envelope (the preferred method).
b. If unenveloped, be sealed or glued completely along all four sides.
2-1.2 Paper Weight
Mailers must use mailpieces constructed from high tear strength paper
stock. For envelopes or letter-sized mailpieces sealed along all four sides,
mailers must use paper with a minimum basis weight of 50-pound book-
grade paper. The conversion table in Exhibit 2-1.2
provides a cross-
reference for basis weights of various papers.
Note: In this Publication 25, all references to paper basis weight are for
book-grade paper unless otherwise stated.
2-1.3 Designing Letter and Reply Mail
12 Publication 25
Exhibit 2-1.2
Paper Basis Weight Conversion Table
2-1.3 Dimensions and Shape
Each machinable or automation letter-size piece must be rectangular and
must meet the following standards (see chapter 4
for booklets and folded
self-mailers):
a. For length, no more than 11-1/2" or less than 5".
b. For height, no more than 6-1/8" or less than 3-1/2".
c. For thickness, no more than 1/4" or less than either of the following:
(1)
0.007
"
thick if no more than 6
"
long and 4-1/4
"
high.
(2)
0.009
"
thick if either more than 6
"
long or 4-1/4
"
high, or both.
2-1.4 Maximum Weight
The following maximum weight limits apply:
a. Machinable enveloped letters and cards: 3.5 ounces.
b. Automation enveloped letters and cards: 3.5 ounces.
c. Booklets and folded self-mailers: 3 ounces.
Paper basis weight is based on the weight of 500 sheets of one of the
following grades of paper:
25" x 38" sheets of book-grade paper.
17" x 22" bond-grade paper.
20" x 26" sheets of cover-grade paper.
24" x 36" sheets of newsprint.
For example, if 500 sheets of book-grade paper weigh 39 pounds, the paper is
considered 39-pound book paper.
Equivalent Values
Book Weight Bond Weight Cover Weight Newsprint Weight
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
Machinable and Automation Letters and Cards 2-1.10
November 2018 13
2-1.5 Heavy Letter Mail (More Than 3 Ounces)
Heavy letter mail — i.e., letter-size pieces more than 3 ounces — must be in
a sealed envelope, may not contain stiff enclosures, and must have an
Intelligent Mail barcode (IMb) with a routing code in the address block.
2-1.6 Postcard
Mailpiece designers must prepare postcards from paper stock meeting the
industry standard for a basis weight of 75 pounds or greater, with less than
71.25 pounds (measured weight for 500 25" by 38" sheets). The Postal
Service does not recommended high-bulk stock. The stock must be free
from ground wood unless coated with a substance adding to the stock’s
ability to resist an applied bending force. A double postcard not prepared
with all edges sealed must have the folded edge at the top or bottom. The
open edge of the double postcard must be parallel to the address and must
be secured with one tab (or other permitted closure) in the middle of the
length. Pieces claimed at First-Class Mail automation card prices must meet
the standards in the DMM.
2-1.7 Aspect Ratio
The aspect ratio (i.e., the length of the mailpiece divided by height) must be
between 1.3 and 2.5, inclusive. For definitions of length and height,
see chapter 1
.
2-1.8 Wraps and Closures
An automation-compatible letter-size mailpiece may not be polywrapped,
polybagged, or shrinkwrapped; may not have clasps, strings, buttons, or
similar closure devices; and may not have protrusions that might impede or
damage the mail or mail processing equipment.
2-1.9 Staples and Saddle Stitching
Mailpiece designers may use staples or saddle stitching only on booklet-type
mailpieces to join the bound edge (spine). Inserted staples or stitching must
be parallel to the bound edge, must be set tightly and securely, and must
have no protrusions that might impede or damage the mail or mail
processing equipment.
2-1.10 Rigid and Odd-shaped Items
The Postal Service prohibits rigid items (e.g., pens, pencils, keys, bottle
caps) within machinable and automation letter-size mailpieces. The Postal
Service permits reasonably flexible items (e.g., credit cards), and it permits
odd-shaped items (e.g., coins and tokens) if firmly affixed to and wrapped
within the contents of the mailpiece and envelope to allow for automated
processing.
2-2 Designing Letter and Reply Mail
14 Publication 25
2-2 Flexibility Standards for Automation Letters
2-2.1 Machinability
To ensure transport through automated mail processing machines, a
mailpiece and its contents must bend easily when subjected to a transport
belt tension of 40 pounds around an 11"-diameter drum.
2-2.2 USPS Services for Flexibility Testing
A mailer requesting flexibility testing for letter-size mailpieces must submit at
least five mailpieces and a written request to the local postmaster or
business mail entry manager for submission to the Pricing and Classification
Service Center (PCSC) at least 6 weeks before the mailing date. The request
must describe mailpiece contents and construction, number of pieces being
produced, and preparation level.
The PCSC evaluates the piece and, if warranted, instructs the mailer to
submit samples to USPS Engineering for testing. The PCSC advises the
mailer of its findings. If the Postal Service approves the mailpiece, the
PCSC’s letter includes a unique number that identifies the piece and that
serves as evidence that the piece meets the relevant standards. The mailer
must include a copy of this letter with each postage statement that the mailer
submits for mailings of the approved piece. If requested by the Postal
Service, the mailer must show that pieces it presents for mailing are the
same as those approved.
2-3 Attachments on Letter-size Mailpieces
2-3.1 Use
A label, sticker, perforated pocket, or release card may appear on a letter-
sized mailpiece that is eligible for automation letter prices, including
barcoded carrier route letters meeting automation standards. Release cards
and perforated pockets may not appear on pieces mailed at First-Class Mail
card prices; other restrictions on attachments to cards may apply. A USPS
Marketing Mail or Periodicals letter with a label, sticker, release card, or
perforated pocket must meet additional
standards. These attachments
must meet additional
standards, including the following:
a. A permanent label or sticker less than 0.007" thick, and a perforated
pocket other than repositionable notes, must be affixed directly to the
outside of the mailpiece with permanent adhesive.
b. A relocatable label must be affixed on the outside of, or on the
contents of, a reply mailpiece.
c. Up to two release cards, each at least 0.007" thick and no more than
0.012" thick, must be secured to a letter with a liner or backing under
DMM 201.3.13.5.
Machinable and Automation Letters and Cards 2-3.4
November 2018 15
d. Attachments may appear on pieces mailed at First-Class Mail,
Periodicals, or USPS Marketing Mail prices only if the applicable
content and eligibility standards permit attachments.
2-3.2 Pressure-sensitive Label
Any pressure-sensitive label or sticker affixed directly to a mailpiece before
mailing must have a minimum peel adhesion to stainless steel of
8 ounces/inch. This standard does not apply to pressure-sensitive labels that
the Postal Service provides to mailers to label bundles for sortation levels.
2-3.3 “Sandwich” Label
A “sandwich” label is a two-part unit — a face stock (top label) attached to a
liner (bottom label) — that is affixed to the mailpiece. The face stock must
have a peel adhesion value of at least 2 ounces/inch with respect to the liner
label and at least 8 ounces/inch when reapplied to stainless steel.
2-3.4 Letter-size Piece With Attached Release Card
A letter-size mailpiece, with one or two attached release cards, must have
the following characteristics:
a. The piece must be between 8" and 9-1/2" long (inclusive). With one
release card affixed, the piece must be between 4" and 6" high
(inclusive); with two release cards affixed, the piece must be between
5-1/2" and 6" high (inclusive).
b. No address element, including any address block barcode, may be
closer than 1" to the right edge of the mailpiece.
c. The surface smoothness must be a maximum of 190 Sheffield Units.
d. Enveloped letters must be made of paper with a minimum 60-pound
book-grade paper and have a maximum thickness of 1/8". Window
envelopes must have only one closed panel address window, no larger
than 1-1/2" x 4-1/4".
e. Card-type letters, not mailed at card prices, must have a maximum
thickness of 0.025" as mailed.
f. All pieces other than enveloped letters and card-type pieces (such as
folded self-mailers and booklets) must have a maximum thickness of
0.1" as mailed. Mailpieces with two affixed release cards must meet
the following additional conditions:
(1)
Pieces requiring tabs must be sealed with 1-1/2
"
nonperforated tabs, unless larger tabs are required by
standards for the specific mailpiece design.
(2) Booklets must have a minimum cover weight of 70-pound book-
grade paper.
(3) Folded self-mailers must have a minimum cover weight of
100-pound book-grade paper.
g. Content insert shift must be no more than 5/8" horizontally and no
more than 1/4" vertically.
h. Release cards must meet the standards in DMM 201.3.13.5.
2-3.5 Designing Letter and Reply Mail
16 Publication 25
2-3.5 Standards for Release Cards
One or two release cards, each at least 0.007" thick and no more than 0.012"
thick, attached to a letter-size mailpiece must have the following
characteristics:
a. Be rectangular, but with allowance for finished corners having a radius
of at least 1/8" up to 1/2".
b. Be between 3" and 3-1/2" long (inclusive) and between 2" and 2-1/2"
high (inclusive). Affix each card with either edge parallel to the length of
the mailpiece. If affixing two cards, affix them on the same side of the
mailpiece, and stack the cards vertically or side-by-side across the
mailpiece length on the non-address side only.
c. Be affixed by machine to ensure adequate adhesion. The Postal
Service does not allow manually affixed attachments.
d. Be affixed 1" (+/- 1/8") from the bottom of the mailpiece. The card must
not interfere with readability of the address, barcode, or postage
information. When affixing two cards to a mailpiece, the following
additional conditions apply:
(1) When affixing the cards on the address side, maintain a space of
at least 1/2" from the leading edge, the trailing edge, and the top
edge.
(2) When affixing the cards to the non-address side, place the right
edge of a card between 5" and 6" from the leading edge of the
mailpiece, but no closer than 1/2" from the trailing edge. Maintain
a space of at least 1/2" from the top edge.
e. Be affixed to a liner (backing) and have the following adhesion
standards:
(1) Adhesive used to affix the backing to the mailpiece must have a
peel adhesion of at least 2 pounds/inch to stainless steel with a
20-minute dwell time, at 300"/minute at 90 degrees per American
Standard Testing Method (ASTM) test D3330F.
(2) Adhesive used to attach the release card to the backing must
have a peel adhesion of at least 1.5 ounces/inch to stainless steel
with a 30-minute conditioning time, at 300"/minute at 90 degrees
per ASTM test D3330F.
2-3.6 Letter-size Pieces With Perforated Pockets
Perforated pockets are permanent attachments to letter-sized mailpieces
that open to reveal a small printed insert.
Perforated pockets may not conceal or contain matter bearing personal
information except as provided in DMM 243.2.2. Perforated pockets may
appear on letter-size USPS Marketing Mail pieces and Periodicals. They are
not considered sealed against Postal Service inspection. When they are
affixed to Periodicals mail, advertising printed on the perforated pocket and
any inserted matter is counted as part of the total advertising content of the
host publication.
Machinable and Automation Letters and Cards 2-3.7
November 2018 17
Mailers may use pockets in lieu of labels to bear a permit imprint indicia
showing that postage is paid if indicia information does not appear on the
perforated panel or on the perforations used to create the perforated panel.
The Postal Service permits a maximum of two perforated pockets on an
eligible letter-size mailpiece that has the following characteristics:
a. Is between 8" and 9-1/2" long (inclusive).
b. Is between 4" and 5-1/2" high (inclusive).
c. Is prepared with a minimum paper basis weight or equivalent as follow:
(1) Envelopes: 60-pound.
(2) Booklets: 70-pound.
(3) Folded self-mailers: 100-pound.
The following requirements also apply:
a. Oversized card-type letters paid at letter prices must have a thickness
of at least .012".
b. Perforated pockets may be affixed to the non-addressed side of
envelopes with one closed panel address window. Perforated pockets
must be placed 1" closer to the trailing edge than the window.
c. If the mailer uses tabs to seal a folded self-mailer prepared with
perforated pockets, the folded self-mailer must be sealed with 1-1/2"
nonperforated tabs placed 1" from the top on the leading and trailing
edges.
2-3.7 Standards for Perforated Pockets
A mailer may attach perforated pockets to letter-size mailpieces under the
following conditions:
a. The perimeter of the pocket is affixed with permanent glue with a
minimum adhesive strength of 2 pounds/inch to stainless steel with
20-minute dwell time at 300"/minute at 90 degrees per ASTM Test
D3330F.
b. The attached material has a minimum tear strength of 100 grams of
force (gf) in both the machine direction and cross direction per
Technical Association of the Pulp and Paper Industry (TAPPI) T414.
c. The cut/tie ratio for perforation is 1:1 with a minimum tie size of
1 millimeter (mm). One double cut may appear at the lower trailing
edge corner of the perforated panel of the pocket.
d. The pocket has the following characteristics:
(1) Is between 1-1/2" and 2-3/4" in both length and height.
(2) Has an affixed area no more than 0.012" thick and a perforated
panel no more than 0.03" thick. Perforated pockets may not
exceed the thickness of the host mailpiece. They may not cause
the host to have an uneven surface and must not interfere with
readability of the address, barcode, or postage information.
e. The length of each pocket is parallel to the length of the host mailpiece.
2-3.7 Designing Letter and Reply Mail
18 Publication 25
f. The pocket is attached as follows:
(1) To the address side of a mailpiece:
(a) At least 1" from the bottom and leading edge.
(b) At least 1/2" from the top and trailing edge.
(2) To the non-addressed side of the mailpiece:
(a) At least 1" from the bottom edge.
(b) At least 1/2" from the top.
(c) At least 5" from the left edge but no closer than 1/2" from
the right edge.
g. Two perforated pockets are attached as follows:
(1) Are affixed on the same side of the mailpiece.
(2) Are stacked vertically — do not affix the pockets side by side
across the mailpiece length.
(3) Have a space up to 1/2" between pockets.
November 2018 19
3 Nonmachinable Letters
3-1 Criteria for Nonmachinable Letters
A letter-size piece is nonmachinable if it does not meet the automation or
machinability standards. Windows in paper envelopes do not make
mailpieces nonmachinable.
Attachments do not render mailpieces nonmachinable if allowed by eligibility
standards for the class of mail. Additionally, a letter-size piece is
nonmachinable if it weighs more than 3.5 ounces.
3-2 Additional Criteria for First-Class Mail
Nonmachinable Letters
Letter-size pieces (except cards) that meet one or more of the
nonmachinable characteristics are subject to nonmachinable prices. All
letter-size pieces weighing more than 3.5 ounces are prepared as letters but
charged the flat-sized prices.
3-3 Additional Criteria for USPS Marketing Mail
Nonmachinable Letters
Nonmachinable prices apply to USPS Marketing Mail letter-size pieces that
have one or more of the nonmachinable characteristics. Mailers must
prepare all nonmachinable letters as described in the DMM.
3-4 Additional Criteria for Periodicals Nonmachinable
Letters
Outside-County nonbarcoded and In-County nonautomation letter prices
apply to Periodicals letter-size pieces that have one or more of the
nonmachinable characteristics.
3-5 Designing Letter and Reply Mail
20 Publication 25
3-5 Priority Mail Express and Priority Mail Letters
The Postal Service encourages mailers (but does not require them) to design
and produce Priority Mail Express and Priority Mail letter-size pieces as
machinable letters.
3-6 Nonmachinable Criteria
A letter-size piece is nonmachinable if it has one or more of the following
characteristics (see DMM 601.1.1.2 to determine the length and height of a
mailpiece):
a. Has an aspect ratio (length divided by height) of less than 1.3 or more
than 2.5.
b. Is polybagged, polywrapped, or enclosed in any plastic material, or has
an exterior surface made of a material that is not paper. Windows in
envelopes made of paper do not make mailpieces nonmachinable.
Attachments allowable under applicable eligibility standards do not
make mailpieces nonmachinable.
c. Has clasps, strings, buttons, or similar closure devices.
d. Contains items such as pens, pencils, keys, or coins that cause the
thickness of the mailpiece to be uneven, or contains loose keys or
coins or similar objects not affixed to the contents within the mailpiece.
Loose items may cause a letter to be nonmailable when mailed in
paper envelopes.
e. Is too rigid (does not bend easily when subjected to a transport belt
tension of 20 pounds around an 11"-diameter turn).
f. For pieces more than 4-1/4" high or 6" long, has a thickness less than
0.009".
g. Has a delivery address parallel to the shorter dimension of the
mailpiece.
h. Is a self-mailer that is not prepared according to the DMM.
3-7 Odd-shaped Items in Paper Envelopes
The Postal Service does not permit pens, pencils, key rings, bottle caps, and
other similar odd-shaped items in letter-size or flat-size paper envelopes
unless they are wrapped within the other contents of the envelope to
streamline the shape of the mailpiece and to prevent damage during postal
processing. If an odd-shaped item is not properly wrapped, it could burst
through the envelope and cause injury to employees and damage to USPS
processing equipment. Odd-shaped items that are properly wrapped within
paper envelopes and sent at letter prices may be subject to the
nonmachinable surcharge for First-Class Mail letters or the nonmachinable
prices for USPS Marketing Mail letters.
Nonmachinable Letters 3-9
November 2018 21
3-8 Handling, Content, and Extra Service
Mailers may use certain markings to identify handling, content, and extra
service. The Postal Service does not permit unauthorized markings not
designating price, class, address, handling, content, or extra service. Mailers
may not place extraneous information next to or directly under the last line of
the delivery address, because such information might be confused with
ZIP Codes.
3-9 Window Envelope
For all letter-size mail in window envelopes, every character in the delivery
address, including any Intelligent Mail barcode, marking, or endorsement,
must be completely visible through the window throughout the full range of
movement of the insert bearing the delivery address. Any window envelope
used for letter-size or flat-size mail claimed at automation prices, or for letter-
size mail claimed at Enhanced Carrier Route High-Density or Saturation letter
prices, must meet the barcoding standards for letters. Any window envelope
used for letter-size or flat-size mail must meet the following additional
standards:
a. The address and any Intelligent Mail barcode visible through the
window must be printed on white paper or paper of a very light color.
b. A clear space of at least 1/8" is required between the address block,
which includes any optional endorsement line, and the top, bottom,
and left and right edges of the address window, and must remain when
the insert is moved to its full limits in each direction within the envelope
to ensure efficient processing and delivery. See DMM 202.5.1 (letters)
or 202.5.2 (flats) for barcode clearances when the address block
contains a barcode. For nonautomation price mail, the bottom edge of
the address window must not extend more than 1/8" into the barcode
clear zone as defined in DMM 202.5.3d. Any letter-size envelope
containing a window that intrudes into the barcode clear zone is not
eligible for NCOA
Link
mail processing equipment system processing for
the MOVE Update standard.
c. Window cover material, if used over the address window, must be a
non-tinted clear or transparent material (e.g., cellophane, polystyrene)
and must permit the address, as viewed through the window material,
to meet the print contrast ratio (PCR) standards in DMM 204.1.4 to
ensure efficient processing and delivery. Glassine may be used for
window cover material. All edges of the window cover material must be
glued securely to the envelope. The bottom edge of an address
window must be at least 1/2" (5/8" preferred) from the bottom edge of
the envelope.
d. For letter-size mail, the delivery address window must be parallel with
the longest edge of the envelope. For flat-size mail, the address
window may be parallel with any edge of the envelope.
3-10 Designing Letter and Reply Mail
22 Publication 25
e. For Registered Mail pieces, the opening on a window envelope must
be covered as described in DMM 503.2.3.5.
3-10 Green Diamond Border Envelope
Any envelope or card bearing a green diamond border incurs the appropriate
First-Class Mail price, regardless of mail content or of requested class or
service. When printed on letter-size mail, the border must not enter the OCR
read area or barcode clear zone unless a delivery point barcode or Intelligent
Mail barcode appears in the address block.
November 2018 23
4 Booklets
4-1 Definition
Booklets must have a bound edge (spine). Sheets that are fastened with at
least two staples in the manufacturing fold (saddle stitched), perfect bound,
pressed-glued, or joined together by another binding method that produces
a spine where pages are attached together are considered booklets.
Booklets are open on three sides before sealing, similar in design to a book.
In general, booklets must be uniformly thick. Large bound booklets that are
folded for mailing may qualify for automation and machinable prices if the
final mailpiece remains nearly uniform in thickness and conforms to all other
automation standards.
4-2 Paper
Booklet covers generally must be made with a minimum paper basis weight
of 60-pounds or equivalent. Minimum basis weights are higher for some
designs.
4-3 Physical Standards for Booklets
Booklets must have the following characteristics:
a. Length: Not more than 10.5" or less than 5". See Exhibit 4-6.2
and
Exhibit 4-7
for booklet designs with shorter maximum lengths.
b. Height: Not more than 6" or less than 3.5".
c. Thickness: Not more than 0.25" or less than 0.009".
d. Weight: Not more than 3 ounces.
e. Aspect ratio: Between 1.3 and 2.5, inclusive.
4-4 Designing Letter and Reply Mail
24 Publication 25
4-4 General Booklet Design and Sealing
The position of the final fold and intermediate fold (or spine) for letter-sized
booklets varies according to the specific design of the mailpiece. Open
edges can be sealed with tabs, glue lines, or glue spots. See the exhibits in
sections 4-6
through 4-9 for design and sealing standards by type of design.
Note: When using tabs as seals on the leading edge of small booklets
less than 5" high, mailers may place them closer to the top and bottom
edges than shown in the exhibits in 4-6
, 4-8, and 4-9, and in fact the tabs
may overlap in some cases. Also note the exception of the simple spine
wallet-style design in Exhibit 4-7
, which has a maximum height of 4".
4-5 Tabs, Tape, and Glue
Tabs may be made of paper, translucent paper, vinyl, or plastic. Cellophane
tape may serve as a closure when the saw-toothed cut edge is parallel to the
edge being sealed. Tabs must not contain perforations. For tab size and
placement for folded self-mailers, see DMM 201.3.14. Tab placement is
subject to 1/4" variance in either direction. The following standards also
apply:
a. The Postal Service recommends that translucent paper tabs be made
with a minimum basis weight of 40-pound book-grade paper.
b. The Postal Service recommends that opaque paper tabs be made with
a minimum basis weight of 60-pound book-grade paper with a tear
strength of at least 56 gf in either the machine direction or the cross
direction.
c. When a barcode clear zone is required (see DMM 202.5.1), tabs in the
barcode clear zone must have a paper face meeting the standards for
background reflectance and, if the mailer does not preprint the
barcode, the standards for acceptance of water-based ink.
d. Vinyl tabs and cellophane tape closures are not acceptable within the
barcode clear zone.
e. Tabs must be tight against the edge of the mailpiece. The Postal
Service recommends a maximum overhang of 1/16".
f. Glue spots may serve in lieu of tabs (as indicated in Exhibit 4-5
f) and
must be placed within 3/4" of the open edges.
Exhibit 4-5f
Glue Spot Placement
Booklets 4-6.2
November 2018 25
g. Continuous glue lines may serve as cover-to-cover seals for specific
designs (as indicated in Exhibit 4-5
g). When glue serves as a sealing
method, it must be placed along the length of the open edge and end
no more than 3/4" from the open ends unless standards require use of
a continuous 1/8" wide glue line under 4-5
h. For folded self-mailers
see 2-3.4
b.
Exhibit 4-5g
Glue Line Placement
h. Continuous 1/8"-wide glue lines must be placed along the length of the
open edge and end within 1/4" of the open ends. The selvage along the
open edge must not exceed 1/4". The Postal Service prefers glue lines
created with a permanent adhesive that is not tacky when dry.
i. Die-cut flaps (i.e., those with irregular shapes) must be well sealed to
the non-address side panel using tabs, glue spots, or elongated glue
lines; however, the Postal Service highly recommends a 1/8"
continuous glue line that follows and seals the contour of the shape.
4-6 Simple Spine Booklets
4-6.1 Overview
The spine forms the bottom edge of the mailpiece. The length or method
used to seal the booklet determines the weight of the paper forming the
cover. See 4-6.2
through 4-6.5 for various types of simple spine booklets.
4-6.2 Simple Spine Booklets
Simple spine booklets have the following characteristics:
a. Maximum weight: 3 ounces.
b. Maximum length: 9.5" unless noted.
c. Maximum height: 6".
d. Cover paper weight: 80-pound book-grade paper unless noted.
See Exhibit 2-1.2
.
4-6.3 Designing Letter and Reply Mail
26 Publication 25
See Exhibit 4-6.2
for various types of simple spine booklets and further
descriptions.
Exhibit 4-6.2
Simple Spine Booklets
4-6.3 Lightweight Simple Spine Booklets
Lightweight simple spine booklets have the following characteristics:
a. Maximum weight: 0.8 ounce.
b. Maximum length: 10.5".
c. Maximum height: 6".
d. Cover paper weight: 70-pound book-grade paper unless noted.
See Exhibit 2-1.2
.
Type Description
Basic Cover 5" to 9" long: minimum 50-pound book-grade
paper.
Over 9" up to 10.5" long: minimum 60-pound
book-grade paper.
The front cover may be up to a maximum of
0.25" shorter than pages and rear cover.
Nonperforated 1.5" tabs.
Place one tab on the leading and trailing
edges within 1" from the top; place one tab
on the lower leading edge 0.5" from the
bottom.
Internal Flap Cover Minimum 80-pound book-grade paper.
Extended front folded over enclosed pages to
create a nonperforated inner flap. Flap sealed
inside of back cover.
Seal with a continuous glue line along flap
(preferred) or 1" glue spots as described in
4-5f.
Cover-to-Cover Cover Minimum 80-pound book-grade paper.
Cover extends no more than 5/8" beyond
inner pages.
Seal with a continuous glue line along
extended cover as described in
4-5g
(preferred) or 1" glue spots as described in
4-5f.
Booklets 4-6.4
November 2018 27
See Exhibit 4-6.3
for various types of lightweight simple spine booklets and
further descriptions.
Exhibit 4-6.3
Lightweight Simple Spine Booklets
4-6.4 Mid-weight Simple Spine Booklets
Mid-weight simple spine booklets have the following characteristics:
a. Weight: Over 0.8 ounce up to 1.6 ounces.
b. Maximum length: 10.5".
c. Maximum height: 6".
d. Cover paper weight: 70-pound book-grade paper unless noted.
See Exhibit 2-1.2
.
Type Description
Cover-to-Cover Cover extends no more than 5/8" beyond
inner pages.
Seal with a continuous glue line.
External Flap Addressed side of the cover extends over all
pages on the back to create a flap.
Flap length: At least 1.5" wide when
measured down from the top edge. It may be
longer, but it cannot be closer than 1" from
bottom edge.
Flap attaches to the outside of the non-
addressed side of the cover.
Seal with a continuous glue line.
Internal Flap Addressed side of the cover extends over
internal pages to
create an inside flap.
Flap length: At least 1.5" wide when
measured down from the top edge.
Flap attaches to the inside of the non-
addressed side of the cover.
Seal with a continuous glue line.
4-6.5 Designing Letter and Reply Mail
28 Publication 25
See Exhibit 4-6.4
for various types of mid-weight simple spine booklets and
further descriptions.
Exhibit 4-6.4
Mid-weight Simple Spine Booklets
4-6.5 Heavy-weight Simple Spine Booklets
Heavy-weight simple spine booklets have the following characteristics:
a. Weight: Over 1.6 ounces up to 3 ounces.
b. Maximum length: 10.5".
c. Maximum height: 6".
d. Cover paper weight: 70-pound book-grade paper unless otherwise
noted. See Exhibit 2-1.2
.
Type Description
Cover-to-Cover Cover extends no more than 5/8" beyond
inner pages.
Seal with a continuous glue line and one
nonperforated tab 0.5" from the bottom
leading edge. Minimum tab size: 1.5".
External Flap Addressed side of the cover extends over all
pages on the back to create a flap.
Flap length: At least 1.5" wide when
measured down from the top edge. It may be
longer, but it cannot be closer than 1" from
bottom edge.
Flap attaches to the outside of the non-
addressed side of the cover.
Seal with a continuous glue line and one
nonperforated tab 0.5" from the bottom
leading edge. Minimum tab size: 1.5".
Internal Flap Addressed side of the cover extends over
internal pages to
create a flap.
Flap length: At least 1.5" wide when
measured down from the top edge.
Flap attaches to the inside of the non-
addressed side of the cover.
Seal with a continuous glue as described in
4.5h, and one nonperforated tab 0.5" from the
bottom leading edge. Minimum tab size: 1.5".
Booklets 4-7
November 2018 29
See Exhibit 4-6.5
for various types of heavy-weight simple spine booklets
and further descriptions.
Exhibit 4-6.5
Heavy-weight Simple Spine Booklets
4-7 Wallet-style Booklets
On a w
allet-style
booklet, a
spine forms the bottom edge. Wallet style
booklets must be sealed with nonperforated tabs. Tab size and placement
are dictated by the weight of the booklet.
Wallet-style
booklets have the following characteristics:
a. Maximum weight: 2.5 ounces.
b. Maximum length: 5.2" to 8".
c. Maximum height: 4".
d. Cover paper weight: 70-pound book-grade paper, except as noted in
Exhibit 4-7
. See Exhibit 2-1.2.
Type Description
Cover-to-Cover Cover extends no more than 5/8" beyond
inner pages.
Seal with a continuous glue line as described
in 4.5 and two 1.5" nonperforated tabs. Place
one tab on the leading edge 0.5" from
bottom; place one tab 1" from top leading
edge.
External Flap Addressed side of the cover extends over all
pages on the back to create a flap.
Flap length: At least 1.5" wide when
measured down from the top edge. It may be
longer, but it cannot be closer than 1" from
bottom edge.
Flap attaches to the outside of the non-
addressed side of the cover.
Seal with a continuous glue line and two 1.5"
nonperforated tabs. Place one tab on the
leading edge 0.5" from bottom; place one tab
1" from top leading edge.
Internal Flap Addressed side of the cover extends over
internal pages to
create a flap.
Flap length: At least 1.5" wide when
measured down from the top edge.
Flap attaches to the inside of the non-
addressed side of the cover.
Seal with a continuous glue line and two 1.5"
nonperforated tabs. Place one tab on the
leading edge 0.5" from bottom; place one tab
1" from top leading edge.
4-8 Designing Letter and Reply Mail
30 Publication 25
See
Exhibit 4-7
for a type of w
allet-style
booklet and a further description.
Exhibit 4-7
Wallet-style Booklet
4-8 Oblong Booklets
Oblong booklets have a spine on the leading (shorter) edge.
Oblong
booklets have the following characteristics:
a. Maximum weight: 3 ounces.
b. Maximum length: 10.5".
c. Maximum height: 6".
d. Cover paper weight: 70-pound book-grade paper unless otherwise
noted. See Exhibit 2-1.2
.
Type Description
Cover Entire booklet must use 60-pound book-
grade paper, or the cover can use 70-pound
book-grade paper and the inner pages
50-pound book-grade paper.
Tabs: Booklets up to 2 ounces must be
sealed with 1.5" nonperforated tabs placed
1-1/4" from bottom leading and trailing edge;
booklets over 2 ounces must be sealed with
2" nonperforated tabs placed 3/4" from
bottom leading and trailing edge. In either
case, the vertical tolerance for tab placement
is ±1/8".
Booklets 4-9
November 2018 31
See Exhibit 4-8 for various types of o
blong
booklets and further
descriptions.
Exhibit 4-8
Oblong Booklets
4-9 Quarter-folded Booklets
Quarter-folded booklets are mailpieces that are bound and then folded to
letter-size. The folded spine may be the leading edge or at the top of the
booklet. If necessary, the booklet may have the spine as the trailing edge —
however, the Postal Service does not recommend this configuration. The
cover must be at least 40-pound book-grade paper. Folded booklets must
be sealed with nonperforated 1.5" tabs.
Quarter-folded booklets
have the following characteristics:
a. Maximum weight: 3 ounces.
b. Maximum length: 10.5" unless noted.
c. Maximum height: 6".
d. Cover paper weight: See Exhibit 4-9
.
Type Description
All Tab Cover 5" to 9" long: 60-pound book-grade paper.
Over 9" up to 10.5" long: 70-pound book-
grade paper.
Place two 1.5" nonperforated tabs on the top
edge and one tab on the trailing edge. Place
the top tabs 1" from left and right edges.
Place one 1.5" nonperforated tab in the
middle of the trailing edge.
Internal Flap 5" to 9" long: 60-pound book-grade paper.
Over 9" up to 10.5" long: 70-pound book-
grade paper.
The front or back cover sheet is extended on
the trailing edge and folded over the
nonrecessed internal pages. The flap is
sealed inside the opposite cover sheet with
glue. Extended front and back covers with
recessed internal pages are not allowed with
glue line seals.
Seal with a continuous glue line. Place two
1.5" nonperforated tabs on the top edge 1"
from the leading and trailing edges.
4-10 Designing Letter and Reply Mail
32 Publication 25
See Exhibit 4-9 for various types of q
uarter-folded booklets
and further
descriptions.
Exhibit 4-9
Quarter-folded Booklets
4-10 Folded Self-mailers
The Postal Service routinely updates folded self-mailer reference material.
Mailers can verify the most recent information at pe.usps.com.
Type Description
Vertical Spine Minimum 40-pound book-grade paper.
Place two 1.5" nonperforated tabs on leading
edge and one tab on trailing edge. Place
upper tabs 1" from the top edge. Place lower
leading tab 0.5" from the bottom edge.
Horizontal Spine Up to 9" long: 50-pound book-grade paper.
Over 9" up to 10.5" long: 60-pound book-
grade paper.
Tabs: Booklets up to 2 ounces must be
sealed with 1.5" nonperforated tabs; booklets
over 2 ounces must be sealed with 2"
nonperforated tabs.
Spine at top on address-side panel.
Place one tab on the leading and trailing edge
1" from the top; place one tab on the lower
leading edge 0.5" from the bottom.
November 2018 33
5 Letter-size Pieces Containing Discs
(CDs or DVDs)
5-1 Basic Standards for Discs in Letter-size Mailpieces
A letter-size mailpiece containing one disc and meeting the general
standards in DMM 201.3.0 and the specific standards in DMM 201.3.4.3 is
considered automation-compatible. If a mailpiece has one enclosed disc not
meeting these standards, the Postal Service must test and approve it for
automation-compatibility. For this purpose, a mailer must submit five sample
mailpieces and a written request to the local postmaster or business mail
entry manager for submission to the Pricing and Classification Service
Center (PCSC).
5-2 Disc Size and Placement
Position the disc symmetrically at the vertical centerline and as near to the
top edge of the mailpiece as is practical. Secure the disc to prevent it from
shifting more than 1/2" in any direction. T
he
maximum
characteristics for a
disc are as follows:
a. Diameter: 120 mm (4.7").
b. Thickness: 2 mm (0.08").
5-3 Dimensions and Shape Standards for Automation-
compatible Enveloped Letters Containing Disc
Each enveloped letter must meet the basic standards for machinable letters
and have the following characteristics:
a. Length: Not more than 9.75" or less than 7.25".
b. Height: Not more than 6" or less than 5.5".
c. Thickness: Not more than 0.25" or less than 0.009".
d. Weight: Not more than 3 ounces.
5-4 Designing Letter and Reply Mail
34 Publication 25
e. Paper basis weight: Based on the length of the piece, as follows:
(1) Up to 8" long: A minimum 70-pound book-grade paper or
equivalent.
(2) Over 8" and up to 9.75" long: A minimum 80-pound book-grade
paper or equivalent.
Note: If the mailpiece is made of the minimum basis weight paper,
the disc must be contained in a protective sleeve.
f. Window envelope: Not allowed unless the Postal Service has tested
and approved it.
5-4 Dimensions and Shape Standards for Automation-
compatible (Unenveloped) Disc Carriers
Each unenveloped disc carrier must meet the basic standards for a
machinable letter in DMM 201.1.0 and have the following characteristics.
a. Length: Not more than 9.75" or less than 7.25".
b. Height: Not more than 6" or less than 5.5".
c. Thickness: Not more than 0.25" or less than 0.009".
d. Weight: Not more than 3 ounces.
e. Paper basis weight: Minimum 75-pound book-grade paper or
equivalent. The paper stock must meet the industry standard. The
stock must be free from groundwood unless it is coated with a
substance adding to the stock’s ability to resist an applied bending
force.
f. Folds or perforations: Must be parallel to the address.
g. Tabs: Must meet the requirements for pieces prepared with folds or
perforations parallel to the address.
5-5 Unacceptable Characteristics for Automation-
compatible Letter-size Pieces with Discs
Discs in letter-sized envelopes and unenveloped disc carriers may not be
enclosed in packaging such as plastic “clamshells,” plastic “jewel cases,” or
inflexible cardboard sleeves.
November 2018 35
6 Business Reply Mail
6-1 Overview
For an annual permit fee, a Business Reply Mail (BRM) permit is available for
distributing business reply cards, envelopes, self-mailers, cartons, and
labels. BRM allows the permit holder to receive First-Class Mail and Priority
Mail items back from customers by paying postage and fees only on the mail
returned. The BRM permit holder guarantees payment of First-Class Mail
postage plus a per-piece charge for pieces returned by the Postal Service.
(See Notice 123, Price List.)
When designing a BRM mailpiece or label, a mailer must consult with the
local Post Office. The piece must conform to a specific format to qualify as
BRM, including a unique ZIP+4 Code assigned by the Postal Service.
BRM templates are available at https://pe.usps.com/text/qsg300/
Q505.htm#ep1026965.
The Postal Service also offers an online self-service tool that allows mailers
to create approved USPS camera-ready artwork for domestic reply mail
pieces in just a few steps. The USPS Automated Business Reply Mail
(ABRM) application is a web-based, self-service tool to assist reply mail
mailers in creating domestic BRM, Courtesy Reply Mail (CRM), and Qualified
Business Reply Mail (QBRM) artwork for card-size and letter-size mailpieces.
The ABRM tool allows mailers to design and create approved USPS camera-
ready artwork with an Intelligent Mail barcode (IMb). Mailers can then place
their IMb either above the address block or in the barcode clear zone (lower-
right corner) of the piece and can even add an image or logo related to the
mailpiece. Mailers can download artwork files in PDF and EPS formats and
can store these files in the system library for future use. Another exciting
feature of the ABRM tool allows mailers to authorize third-party vendors or
service providers to create artwork on their behalf.
A client must provide its service provider with pertinent information such as
its PostalOne! BRM permit number, mailer ID, and assigned BRM ZIP+4
Code.
Access the ABRM tool through the Business Customer Gateway Web site at
https://gateway.usps.com/eAdmin/view/knowledge?id=ABRM
.
In addition to the ABRM tool, the Postal Service has implemented the MDA
Support Center. This center connects mailers with a mailpiece design analyst
(MDA) who will provide timely assistance and evaluations of mailpiece
design, including reply mail. The MDA Support Center hours of operation are
Monday through Friday between 7:00 am and 5:00 pm CT. Mailers may
6-1 Designing Letter and Reply Mail
36 Publication 25
contact the MDA Support Center by dialing 855-593-6093, or by sending a
request via email to [email protected].
Before a mailer performs final printing or electronic distribution of reply mail
pieces, the Postal Service must approve a proof for regular BRM or QBRM,
both of which must include the applicable IMb. The Postal Service does not
permit delivery point barcodes on BRM pieces or QBRM pieces.
Exhibit 6-1
a provides layout guidelines for a BRM envelope, and Exhibit 6-1b
provides a BRM checklist. For requirements on reusable envelopes using
BRM with two-way indicia, see DMM 601.6.0.
BRM templates are available on the Postal Explorer Web site at
pe.usps.com; under the “Business Solutions” tab in the top blue bar, select
Mailpiece Design.
Exhibit 6-1a
Business Reply Mail Layout Guidelines
Business Reply Mail 6-1
November 2018 37
Exhibit 6-1b
Business Reply Mail Checklist
Business Reply Mail Checklist
This checklist is provided to assist mailers with designing Business Reply Mail.
1. Printing and Print Reflectance
__ Not handwritten, typewritten, or handstamped.
__ No printed borders on letter-size.
__ All ink colors are acceptable if the piece meets the appropriate reflectance standards in
DMM 505.
2. “No Postage Necessary” Imprint
__ Properly worded (all capital letters recommended):
NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES
__ Properly positioned.
__ Upper-right corner of the address side of the piece: Not more than 1-3/4" from the right edge
of the piece.
__ Printed directly on piece
1
.
3. Business Reply Legend
__ Properly worded:
BUSINESS REPLY MAIL
BUSINESS REPLY LABEL
__ All capital letters.
__ Letters at least 3/16" high.
__ Printed directly on piece
1
.
4. Permit Number
__ Properly worded:
FIRST-CLASS MAIL PERMIT NO. [NO., CITY, STATE]
(Representing the permit holder’s number and Post Office that issued the permit.)
__ Directly below the business reply legend.
__ All capital letters.
__ Printed directly on piece
1
.
5. Postage Endorsement
__ Properly worded:
POSTAGE WILL BE PAID BY ADDRESSEE
__ Directly below First-Class Mail and permit number, city, and state.
__ All capital letters.
__ Printed directly on piece
1
.
6. Delivery Address
__ Complete address:
Permit holder’s name
Delivery address
City, state and BRM ZIP Code
__ Within OCR read area
2
.
__ At least 1/2" between ZIP Code and horizontal bars.
__ Correct ZIP Code for BRM.
__ Permit holder’s name printed directly on piece
1
.
6-1 Designing Letter and Reply Mail
38 Publication 25
Business Reply Mail Checklist (continued)
7. Horizontal Bars — Optional with correct Intelligent Mail barcode
__ Directly below “No Postage Necessary” imprint.
__ Uniform length at least 1".
__ 1/16"–3/16" thick and evenly spaced.
__ Do not extend lower than 5/8" from bottom edge of piece.
8. Facing Identification Mark (FIM)
__ FIM C required.
__ FIM clear zone boundaries:
Left: 3" from right edge of the piece.
Right: 1-3/4" from right edge of piece.
Top: top edge of piece.
Bottom: 5/8" from top edge of piece.
__ FIM bars 5/8" high, ± 1/8".
__ FIM bars 1/32" wide, ± 0.008".
__ Right edge of rightmost bar 2" from right edge of piece, ± 1/8".
__ Tops of bars no lower than 1/8" from top edge of piece.
__ Bottom of bars no lower than 5/8" from top edge of piece, ±1/8".
__ Positional skew (slant of the entire FIM) ± 5 degrees.
__ Rotational skew (slant of individual FIM bars) ± 5 degrees.
__ 30 percent reflectance between FIM and background.
9. Company Logo
__ On letter-size, no lower than 5/8" from bottom edge of piece.
10. Intelligent Mail Barcode (IMb) and Delivery Point Barcode
1,2,3,4,5
__ Barcode clear zone:
Left: 4-3/4" from right edge of piece.
Right: Right edge of piece.
Top: 5/8" from bottom edge of piece.
Bottom: Bottom edge of piece.
__ Barcode on mailpiece (barcode read area):
Horizontally, leftmost bar within 3-1/2" to 4-1/4" from right edge of piece.
Vertically, entire barcode within 3/16" to 1/2" from bottom edge of piece.
1
See DMM 505.1 for window envelopes.
2
See DMM 202.2 for OCR read area.
3
See DMM 202.5 for placement of barcode in address block.
4
See DMM 204.1.for IMb Specifications.
5
See DMM 505.1 for complete QBRM specifications; only IMb can be used on QBRM pieces.
Business Reply Mail 6-3
November 2018 39
6-2 Dimensions
Postcards that exceed the normal postcard dimensions but meet the letter-
size dimensions are mailable, but they incur the regular First-Class Mail letter
price. See Exhibit 6-2
for dimensions for postcards.
Barcoded pieces measuring more than 6" long or 4-1/4" high must be at
least 0.009" thick.
Additional standards apply to QBRM pieces.
Exhibit 6-2
Dimensions for Postcards
6-3 Ink/Paper Colors and Type Styles
Not all colors of paper and/or ink and type styles are compatible with
automated equipment. Contact your local Post Office for guidance.
Letter-size Prices Card Prices
Minimum Maximum Minimum Maximum
Length 5" 11-1/2" 5" 6"
Height 3-1/2" 6-1/8" 3-1/2" 4-1/4"
Thickness 0.007" 0.016" 0.007" 0.016"
Designing Letter and Reply Mail
40 Publication 25
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November 2018 41
7 Courtesy Reply Mail
7-1 Overview
Courtesy Reply Mail (CRM) consists of preaddressed postcards or envelopes
that the mailer provides to customers, both to expedite their responses and
to provide more accurate delivery. It differs from BRM in that no fees are
required and the respondent is responsible for applying the correct postage
before mailing back the card or envelope.
The mailer prepares CRM with the correct address and barcode to take
advantage of automated USPS processing. It is a good choice when you
wish to direct replies of payments to an address that is different from your
usual mailing address, such as a customer service center or a payment
processing location.
The Postal Service provides the mailer, at no charge, the facing identification
mark (FIM) and the appropriate barcode that the mailer prints on CRM
pieces.
Exhibit 7-1
a provides layout guidelines for a CRM envelope, and Exhibit 7-1b
provides a CRM checklist.
7-1 Designing Letter and Reply Mail
42 Publication 25
Exhibit 7-1a
Courtesy Reply Mail Layout Guidelines
Courtesy Reply Mail 7-2
November 2018 43
Exhibit 7-1b
Courtesy Reply Mail Checklist
7-2 Barcodes
Delivery point barcodes or Intelligent Mail barcodes may appear either in the
address block or in the lower-right barcode clear zone.
CRM templates are available on the Postal Explorer Web site at
pe.usps.com; under the “Business Solutions” tab in the top blue bar, select
Mailpiece Design.
Courtesy Reply Mail Checklist
This checklist is provided to assist mailers with designing Courtesy Reply Mail.
1. Facing Identification Mark (FIM)
__ FIM A is used.
__ FIM A is properly positioned. Minimum PRO is met.
__ No extraneous printing is in the FIM clear zone.
2. Postage Area: Customer Reminder to Affix Postage (optional element)
__ Area extends no more than 1-3/4 inches from the right edge of the mailpiece.
3. Delivery Address Block
__ Delivery address line (street address/PO box number) is directly above city/state/ZIP+4 line.
__ ZIP Code corresponds with barcode.
__ City/state/ZIP+4 line is at least 5/8 inch from bottom and no higher than 2-1/4 inches from
bottom edge of mailpiece.
__ For window envelopes only: Minimum clearances between address block (including barcode)
and window edges are maintained on all sides during “insert shift.”
4. Barcode
__ Barcode is correctly positioned (in address block or in barcode clear zone).
__ Barcode is readable.
__ Print reflectance minimum is met.
__ If barcoded in the barcode clear zone: There is no extraneous printing or other matter in the
zone.
5. Other
__ Aspect ratio is met.
__ Dimensions are within the letter-size standards.
__ Piece is at least 3-1/2 inches high and at least inches long.
__ If no longer than 4-1/4 inches by 6 inches, piece is at least 0.007 inches thick, and at least
0.009 inches thick if piece is large than 4-1/4 inches by 6 inches.
__ For official mail only: Endorsed “Official Business, Penalty for Private Use $300” in upper left
area.
7-3 Designing Letter and Reply Mail
44 Publication 25
7-3 Dimensions
Postcards that exceed the normal postcard dimensions but that meet the
letter-size dimensions are mailable, but they incur the regular First-Class Mail
letter price. See Exhibit 6-2
for dimensions of postcards.
Barcoded pieces measuring more than 6" long or 4.25" high must be at least
0.009" thick.
7-4 Ink/Paper Colors and Type Styles
Not all colors of paper and/or ink and type styles are compatible with
automated equipment. Contact your local Post Office for guidance.
November 2018 45
8 Meter and PC Postage Reply Mail
8-1 Overview
Under the following conditions, mailers may use indicia generated by any
postage evidencing system to prepay reply postage on Priority Mail Express
and Priority Mail pieces (when the price is the same for all zones), on
First-Class Mail pieces, and on single-piece-price Media Mail and Library
Mail pieces:
a. The postage amount must be sufficient to prepay the full postage due.
b. Indicia must be printed directly on the mailpiece and must appear in
the upper-right corner of the envelope, at least 1/4" from the right edge
of the mailpiece and 1/4" from the top edge of the mailpiece.
c. Indicia must not show the date.
d. Mailpieces must be pre-addressed for return to the authorized user
only.
e. The words “NO POSTAGE STAMP NECESSARY POSTAGE HAS BEEN
PREPAID BY” must be preprinted directly above the address.
f. Mailers may use FIM A on barcoded letter-size First-Class Mail reply
mail except when using PC Postage service.
g. When using PC Postage, mailers must use FIM D for prepaid reply mail
when printing the indicium directly on the mailpiece.
h. The address side must appear as described in this section and as
shown in Exhibit 8-1
a — the mailer may not add anything else.
Exhibit 8-1
a provides layout guidelines for a
Meter or PC Postage reply mail
envelope, and Exhibit 8-1b provides a
Meter or PC Postage reply mail
checklist.
8-1 Designing Letter and Reply Mail
46 Publication 25
Exhibit 8-1a
Meter or PC Postage Reply Mail Layout Guidelines
Meter and PC Postage Reply Mail 8-1
November 2018 47
Exhibit 8-1b
Meter or PC Postage Reply Mail Checklist
Meter or PC Postage Reply Mail Checklist
This checklist is provided to assist mailers with designing Meter or PC Postage Reply Mail.
1. Facing Identification Mark (FIM)
__ FIM A is used.
__ FIM is properly positioned.
__ Minimum Print Reflectance Difference (PRD) is met.
__ No extraneous printing is in the FIM clear zone.
2. Meter or PC Postage Stamp
__ Stamp is properly positioned.
__ Stamp contains no date.
__ Stamp is legible.
__ Postage is sufficient for type and weight of piece — for example: First-Class and ounce(s), or
Priority Mail Flat-Rate and ounce(s) or pound(s).
3. “NO POSTAGE STAMP NECESSARY POSTAGE HAS BEEN PREPAID BY”
__ Letters are all capitals.
__ Letters are at least 3/16" high.
__ Endorsement is properly worded.
4. Delivery Address Block
__ Delivery address line (street address/PO Box number) is directly about city/state/ZIP+4 line.
__ ZIP+4 Code corresponds with ZIP+4 barcode.
__ City/state/ZIP+4 line is at least 5/8" from bottom edge of piece.
__ City/state/ZIP+4 line is no higher than 2-1/4" from bottom edge of piece.
__ For window envelopes: minimum clearances between address block (including barcode) and
window edges are maintained on all sides during “insert shift.”
5. Barcode and Lower-right Barcode Clear Zone
__ Barcode is correctly positioned (in address block or barcode clear zone).
__ Barcode is readable.
__ Print reflectance minimum is met.
__ If barcoded in the barcode clear zone: no extraneous printing or other matter is in the zone.
6. Other
__ Aspect ratio is met.
__ Dimensions are within the letter-size standards and piece is automation compatible.
__ Piece is at least 5" long.
__ Piece is at least 3-1/2" high.
__ If no larger than 6" long by 4-1/4" high, piece is at least 0.007" thick, and at least 0.009" thick
if piece is larger than 6" long or 4-1/4" high" or both.
__ For official mail: endorsed “Official Business, Penalty for Private Use $300” in the upper-left
area.
8-2 Designing Letter and Reply Mail
48 Publication 25
8-2 Barcodes
Delivery point barcodes or Intelligent Mail barcodes on letter-size pieces may
appear either in the address block or in the lower-right barcode clear zone.
8-3 Dimensions
Postcards that exceed the normal postcard dimensions but that meet the
letter-size dimensions are mailable, but they incur the regular First-Class Mail
letter price. See Exhibit 6-2
for dimensions of postcards.
Barcoded pieces measuring more than 6" long or 4-1/4" high must be at
least 0.009" thick.
Additional standards apply to QBRM pieces.
8-4 Ink/Paper Colors and Type Styles
Not all colors of paper and/or ink and type styles are compatible with
automated equipment. Contact your local Post Office for guidance.
November 2018 49
9 Permit Reply Mail
9-1 Overview
Permit reply mail (PRM) enables a permit imprint permit holder to receive
First-Class Mail and Priority Mail pieces back from customers by prepaying
postage for reply mail pieces at the time of mailing. Mailers must distribute
PRM pieces only as part of a First-Class Mail mailing using a permit imprint
(not through any other means). PRM mailers must apply for authorization
through the district manager of Business Mail Entry at the office that holds
the permit imprint account, and they must submit preproduction samples of
PRM pieces to the Postal Service for approval before distribution.
The following additional conditions apply:
a. No extra services (e.g., Certified Mail, insurance, Registered Mail) are
permitted with PRM.
b. The PRM customer may not alter the delivery address on a PRM
mailpiece to redirect it to any address other than the one preprinted on
the piece.
c. The PRM customer must not use PRM to mail any items except those
intended by the permit holder, even when postage is affixed.
d. A letter-size PRM piece containing one standard disc does not incur a
nonmachinable surcharge if the piece meets the standards in
DMM 233.2.8. A flat-size PRM piece containing one standard disc and
weighing no more than 2 ounces incurs postage applicable for a
1-ounce First-Class Mail letter if the piece meets the standards in
DMM 233.2.8.
e. If the Postal Service discovers a PRM format error, the permit holder or
authorized agent receives a written notification of the error. The permit
holder must correct the error and ensure that all future PRM pieces
meet appropriate specifications before reauthorization. The Postal
Service may revoke a PRM authorization because of format errors or
misuse.
f. Each PRM piece must include the format elements shown in
Exhibit 9-1
.
g. PRM mailers may print their pieces with any standard industrial printing
method (offset lithography, digital printing, etc.) — however, the Postal
Service prohibits handwriting, typewriting, or hand-stamping. If you
have questions, contact your local Post Office.
9-1 Designing Letter and Reply Mail
50 Publication 25
h. The imprint “NO POSTAGE NECESSARY IF MAILED IN THE UNITED
STATES” must appear in the upper-right corner of the address side of
the piece, and it must not extend more than 1-3/4" from the right edge
of the piece.
i. The legend “PERMIT REPLY MAIL” must appear on all pieces. The
legend must appear above the address in capital letters at least 3/16"
high and may be surrounded by a rule or border.
j. Directly below the permit reply mail legend, the words “FIRST-CLASS
MAIL PERMIT NO. [NO., CITY, STATE]” (representing the permit
holder’s number and the Post Office that issued the permit) must
appear in capital letters. The permit holder may replace the permit
number and the Post Office with a company permit as described in
9-2
. Directly below that, the endorsement “POSTAGE HAS BEEN
PREPAID BY ADDRESSEE” must appear in capital letters. At the
permit holder’s discretion, the permit number and postage
endorsement may be surrounded by a rule or border.
k. The complete address (including the permit holder’s name, delivery
address, city, state, and ZIP+4) must appear on the piece. PRM pieces
must bear a delivery point barcode or an Intelligent Mail barcode.
l. A FIM C must appear on all letter-size PRM. The FIM C must meet the
physical standards in DMM 202.8.0.
m. A company logo is permitted as follows:
(1) On letter-size PRM, if the logo is placed no lower than 5/8" from
the bottom edge of the piece.
(2) On any piece, if the logo does not interfere with any required
format element.
Mailers may distribute PRM as part of the contents of an outgoing mailing
only by using a valid permit imprint account. See DMM 604.5.0 for the
standards for using permit imprints.
Exhibit 9-1
Permit Reply Mail Format Elements
Permit Reply Mail 9-2
November 2018 51
9-2 Using Company Permit Reply Mail Imprint
A company permit reply mail imprint is one in which the exact name of the
company holding the permit appears in the permit reply mail indicia in place
of the city, state, and permit number. A customer may use a company permit
reply mail imprint if, for 1 year from the date of mailing, the permit holder or
its agent keeps records of each mailing paid with a company permit reply
mail imprint and makes them available for USPS review on request. These
records must include the following information:
a. The weight of a single piece.
b. The total number of pieces mailed.
c. The total postage.
d. The dates and Post Offices of mailing.
The mailer must include a complete sample mailpiece for each mailing.
To create a company permit reply mail imprint, replace the words “PERMIT
NO. [NO., CITY, STATE]” (representing the permit holder’s number and the
Post Office that issued the permit) with “PERMIT PAID BY [COMPANY
NAME]” (representing the name of the company in the delivery address of the
mailpiece) in capital letters.
Designing Letter and Reply Mail
52 Publication 25
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November 2018 53
10Facing Identification Mark (FIM)
10-1 Description and Purpose
10-1.1 Overview
A facing identification mark (FIM) is a pattern of vertical bars printed in the
upper-right portion of a mailpiece, to the left of the postage area. The FIM
tells automated processing equipment some of what it needs to know to do
its job. The FIM allows automatic facing (orientation) of letter-size mail for
cancellation (postmarking). The FIM also identifies reply mail that bears
preprinted barcodes, and the automated processing equipment routes
barcoded mail directly to high-speed barcode sorters.
10-1.2 Using FIMs
The FIM serves to orient and separate certain types of First-Class Mail
pieces during the facing-canceling process. Mailers must use the
appropriate FIM on the following mailpieces:
a. All letter-size BRM — FIM B and FIM C.
b. All letter-size PRM — FIM C.
c. Letter-size CRM and metered reply mail provided as enclosures in
automation-price mailings — FIM A.
d. Letter-size mail with information-based indicia (IBI) printed with
nonfluorescent ink directly onto the envelope by an IBI meter or a
PC Postage system — FIM D.
e. Cards and letter-size envelopes containing absentee balloting
materials — FIM C.
A mailer may not use a FIM on other types of mail, except on a letter-size
envelope with a permit imprint when that envelope is designed for use as a
reusable mailpiece. A FIM used for this purpose must be the appropriate FIM
for the postage payment method on the returned envelope.
10-1.3 Patterns
A FIM is essentially a nine-bit code consisting of bars and no-bar
placeholders. The presence of a bar can be considered a binary “1” (one),
and the absence of a bar can be considered a binary “0” (zero). The required
10-1.3 Designing Letter and Reply Mail
54 Publication 25
FIM pattern depends on the type of mail and the presence of a delivery point
barcode or an Intelligent Mail barcode, as follows:
a. FIM A is for CRM with a preprinted barcode and metered reply mail
with a preprinted barcode. (The binary code
for
FIM A is 110010011.)
b. FIM B is for BRM without a preprinted BRM ZIP+4 barcode. (The binary
code
for
FIM B is 101101101.)
c. FIM C is for BRM with a preprinted BRM ZIP+4 barcode and for PRM
with a
preprinted delivery point barcode. (The binary code
for
FIM C is
110101011.)
d. FIM D is for letter-size First-Class Mail pieces with PC Postage or IBI
printed with
nonfluorescent ink directly on the envelope. (The binary
code
for
FIM D is 111010111.)
e. FIM E is for postcard-size and letter-size First-Class Mail with
customized services. (The binary code
for
FIM E is 101000101.)
See Exhibit 10-1
for FIM patterns.
Exhibit 10-1
FIM Patterns (not drawn to scale)
Pattern Use Barcoded?
Courtesy Reply Mail
Metered Reply Mail
Yes
Business Reply Mail without a
preprinted barcode
No
Facing Identification Mark (FIM) 10-1.3
November 2018 55
Business Reply Mail with a preprinted
barcode
Yes
IBI Meters
PC Postage Systems
Not required (the
meters contain
the same
information
contained is a
barcode)
Customized Services Yes — but IMb
only
Pattern Use Barcoded?
10-2 Designing Letter and Reply Mail
56 Publication 25
10-2 FIM Standards
Ensure that the FIM bars and FIM clear zone meet the following standards:
a. The FIM clear zone must contain no printing other than the FIM pattern.
Exhibit 10-2
shows the configuration of the clear zone and the correct
location of the FIM.
b. The FIM bars must be 5/8" high (±1/8") and 1/32" wide (±0.008").
c. The right edge of the rightmost bar of the FIM must be 2" from the right
edge of the mailpiece (±1/8").
d. The tops of the FIM bars must be no lower than 1/8" from the top edge
of the mailpiece. The tops of the bars may extend over the top edge of
the piece to the back (flap) of the piece as long as at least a 1/2" bar
height is maintained on the address side.
e. The bottoms of the FIM bars need not touch the bottom edge of the
FIM clear zone, but they must not be more than 1/8" above or below
that edge.
Exhibit 10-2
FIM Layout Guidelines (not drawn to scale)
10-3 Print Reflectance Difference
The Postal Service requires a print reflectance difference (PRD) of at least
30 percent in the red and green portions of the optical spectrum between the
background material of the mailpiece and the barcode, when measured with
a USPS or USPS-licensed envelope reflectance meter. (PRD equals the
reflectance of the background minus the reflectance of the ink.) Black ink on
a white background usually satisfies this requirement, and the Postal Service
recommends it.
FIM bars must be printed within the dimensions shown in Exhibit 10-2
. The
bars must be within 5 degrees of perpendicular to the top edge of the
mailpiece.
Facing Identification Mark (FIM) 10-6
November 2018 57
10-4 FIM Positives and Barcodes
The Postal Service provides, at no charge, camera-ready positives of the FIM
that you need to use and a camera-ready print of the barcode representing
the correct ZIP+4 Code and barcode or delivery point barcode as
appropriate for your reply mail address. Do not reduce or enlarge these
positives and prints. Visit pe.usps.com to find your local mailpiece design
analyst or to design camera-ready positive yourself.
10-5 Obtaining FIMs, Barcodes, and ZIP Codes
You can get FIM positives from your postmaster or mailpiece design analyst.
FIMs are also available on Postal Explorer at pe.usps.com; under “Business
Solutions” in the top bar, click on Mailpiece Design.
You can find the templates for your reply mail envelopes on Postal Explorer,
as well as options for obtaining FIMs and barcodes, obtaining permit
numbers, and payment options; under “Business Solutions” in the top bar,
click on Mailpiece Design.
10-6 Importance of Correct Barcodes and FIMs
Even though barcodes representing different delivery points can look nearly
identical, the correct barcode is essential. The barcode used for your regular
mail delivery is different than the barcode used for your BRM.
Printing the wrong barcode on a reply mail piece can direct your mail to the
wrong Post Office. A wrong barcode may delay delivery of your mail.
It is easy to confuse different FIM patterns. Before you format and print reply
mail, be sure that the barcode and FIM are correct for that use.
It is important that the barcode and FIM are positioned properly on reply mail
pieces. If part of the barcode lies outside the read area, the barcode might
not be scanned accurately.
For correct positioning, use Notice 67, Automation Template, which is
available from the Material Distribution Center at 800-273-1509.
Designing Letter and Reply Mail
58 Publication 25
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November 2018 59
11Ink/Paper Information
11-1 Overview
To ensure the machinability of letter-size mail, the quality of the printing is as
important as the placement of the delivery address.
11-2 Ink/Paper Colors and Type Styles
Not all colors of paper and/or ink and type styles are compatible with
automated equipment.
Inverse (or reverse) printing — i.e., light print on a dark background — is not
permitted for automation and machinable mail, including BRM and QBRM
pieces. Paper color is relative to the printing color of the address, barcode,
return address, and postage indicia. It is very important in the barcode clear
zone. The Postal Service recommends that the paper color allow the PRD
(contrast) to conform to the requirements listed in the discussion on
reflectance — see 11-4
.
Regarding type styles and the best readability on USPS machines, the Postal
Service recommends proportional or fixed fonts, or as close to proportional
or fixed fonts as possible (e.g., Arial, Tahoma). Avoid script or styles similar
to Gothic because USPS machines cannot read them well.
11-3 Paper Quality
The Postal Service recommends that the paper or other material used for the
envelope or outermost sheet of the address side of a mailpiece allow the
water-based ink applied by USPS equipment to dry within 1 second without
smearing.
11-4 Reflectance
11-4.1 Overview
Reflectance is the measurement of the light that rebounds from a surface. It
is extremely important that the reflectance of the printed address or barcode
on a mailpiece contrast sufficiently with the background. The contrast helps
11-4.1 Designing Letter and Reply Mail
60 Publication 25
to ensure that USPS processing machines can read the address information
and direct your mail correctly.
This section provides definitions and formulas for determining the reflectance
of mailpiece backgrounds and printing ink, print contrast ratio (PCR), and
print reflectance difference (PRD). Values for these parameters are always
less than one. Decimals and percentages can express the same amount —
for example, 0.65 means the same as 65 percent — and it is easy to convert
between decimals and percentages. Use the tables in Exhibit 11-4.1
a and
Exhibit 11-4.1
b as tools to convert between decimals and fractions (USPS
standards may appear in either format).
Exhibit 11-4.1a
Decimal and Fractional Equivalents — Fractions Divisible by 32, 16, 8,
and 4
Decimals
Fractions
#/32 #/16 #/8 #/4
0.0313 1/32
0.0625 2/32 1/16
0.0938 3/32
0.1250 4/32 2/16 1/8
0.1563 5/32
0.1875 6/32 3/16
0.2188 7/32
0.2500 8/32 4/16 2/8 1/4
0.2813 9/32
0.3125 10/32 5/16
0.3438 11/32
0.3750 12/32 6/16 3/8
0.4063 13/32
0.4375 14/32 7/16
0.4688 15/32
0.5000 16/32 8/16 4/8 2/4
0.5313 17/32
0.5625 18/32 9/16
0.5938 19/32
0.6250 20/32 10/16 5/8
0.6563 21/32
0.6875 22/32 11/16
0.7188 23/32
0.7500 24/32 12/16 6/8 3/4
0.7813 25/32
0.8125 26/32 13/16
0.8438 27/32
0.8750 28/32 14/16 7/8
0.9063 29/32
0.9375 30/32 15/16
0.9688 31/32
Ink/Paper Information 11-4.2
November 2018 61
Exhibit 11-4.1b
Decimal and Fractional Equivalents — Fractions Divisible by 25 and 5
The symbol “R” indicates reflectance. Only diffuse (scattered) reflectance is
of interest. It represents the percentage of incident light diffusely reflected by
a material. A surface perfectly reflecting the incident light has a reflectance of
100 percent, and a surface reflecting only half the incident light has a
reflectance of 50 percent.
See 11-4.2
and 11-4.3 for information regarding PRD and PRC. Note that
mailpiece design analysts can measure PRD and PCR, as well as other
mailpiece characteristics, using the Postal Service Envelope Reflectance
Meter (ERM III).
11-4.2 Print Reflectance Difference
The Postal Service requires reply mail pieces to have a PRD of at least
30 percent. The equation for PRD is as follows:
PRD = (RW – RP) x 100.
Note: “RW” is the reflectance of the background (e.g., the envelope or
card), and “RP” is the reflectance of the ink (e.g., character stroke).
Decimals
Fractions
#/25 #/5
0.0400 1/25
0.0800 2/25
0.1200 3/25
0.1600 4/25
0.2000 5/25 1/5
0.2400 6/25
0.2800 7/25
0.3200 8/25
0.3600 9/25
0.4000 10/25 2/5
0.4400 11/25
0.4800 12/25
0.5200 13/25
0.5600 14/25
0.6000 15/25 3/5
0.6400 16/25
0.6800 17/25
0.7200 18/25
0.7600 19/25
0.8000 20/25 4/5
0.8400 21/25
0.8800 22/25
0.9200 23/25
0.9600 24/25
11-4.3 Designing Letter and Reply Mail
62 Publication 25
11-4.3 Print Contrast Ratio
The Postal Service requires reply mail pieces to have a PCR no greater than
15 percent. The equation for PCR is as follows:
PCR = (RW – RP) ÷ RW x 100.
Note: “RW” is the reflectance of the background (e.g., the envelope or
card), and “RP” is the reflectance of the ink (e.g., character stroke).
11-5 Address Block Measurements
ERM III is a portable desktop scanning device that interfaces to a laptop or
desktop personal computer. It is capable of viewing the barcode and
address block of letter-size and flat-size mailpieces.
The ERM III measures optical properties read by USPS automation
equipment. It examines finished mailpieces bearing address information as
well as the pre-production materials intended for subsequent use in
mailpiece construction. Primarily, the ERM III measures the following:
a. Envelope reflectance.
b. Barcode quality analysis of intelligent mail barcodes or delivery point
barcodes.
c. Opacity.
The meter determines whether there is sufficient contrast between the
printed character/barcode and the envelope background so that USPS
automation equipment can successfully process the mailpiece.
11-6 Intelligent Mail Barcodes, Delivery Point Barcodes,
and FIM Measurements
The Postal Service recommends that mailers use the ERM III to measure
print reflectance and print reflectance difference on delivery point barcodes
and Intelligent Mail barcodes, and on FIM bars to avoid interference with
readability. The same procedures that apply to measuring address blocks
apply to measuring barcodes and FIMs. The Intelligent Mail barcode
specification USPS-B-3200 is available at https://postalpro.usps.com/node/
2190.
November 2018 63
12Barcoding Software and Equipment
12-1 CASS and MASS
The Postal Service has designed the Coding Accuracy Support System
(CASS) certification process in cooperation with the mailing industry to
improve the quality of postal codes — i.e., 5-digit ZIP, ZIP+4, delivery point,
and carrier route codes that appear on mailpieces.
The CASS software certification program provides hardware and software
developers, service bureaus, and commercial mailers a common measure by
which to test the quality of address-matching software. The U.S. Postal
Service National Customer Support Center (NCSC) grades software tests for
CASS certification, and it returns the results to the developer to provide
useful diagnostics for correcting software deficiencies. However, CASS
processing does not measure the accuracy of postal codes in a mailer’s
address file.
CASS certification is valid until the end of the current period. For software to
remain CASS Certified for each period, developers must reapply for
certification and meet the minimum accuracy requirements during Stage II
testing.
Another certification program offered by the CASS Department is the
Multiline Accuracy Support System (MASS). MASS provides certification for
multiline optical character readers (MLOCRs), remote video encoding (RVE)
systems, local video encoding (LVE) systems, and encoding stations to
process address information and apply an accurate delivery point barcode.
The NCSC issues MASS certification once the mailer achieves the required
level of accuracy. MASS certification is a biennial requirement and is valid
from the certification date until the end of any current biennial period. The
Postal Service requires MASS certification for all mailers using MLOCRs,
RVE systems, LVE or encoding stations when printing delivery point
barcodes on mailpieces submitted for mailing at automation prices.
12-2 Designing Letter and Reply Mail
64 Publication 25
12-2 PAVE
The Postal Service has designed the Presort Accuracy, Validation, and
Evaluation (PAVE) program in cooperation with the mailing industry to
evaluate presort software and determine its accuracy in sorting address files
according to DMM standards. PAVE is available only to presort software
developers and vendors (i.e., companies that develop presort software or
perform retail services for those developers). Participation in the PAVE
program is voluntary.
