New Tabbing Requirements for Booklets Receiving

1. New Tabbing Requirements for Booklets Receiving Automation & Machinable Letter Prices BOOKLET Pam Keller Mailpiece Design Analyst Western PA District

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

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

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

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

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

7. New standards for letter-sized booklets FederalRegister published on April 15, 2009 General overview: Definestandards for design, preparation, and sealing of machinable and automation letter-size booklets Describe minimum requirements and provide recommendations based on wide variety of test observations and several years of analysis Provide illustrations of new requirements Minimize mailpiece damage and maximize efficient processing Effective September 8, 2009 How We Implemented the Change

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

9. Dimensions and weight requirements for automation and machinable letter prices Booklets: Height – 3.5 inches to 6 inches Length – 5 inches to 10.5 inches* Thickness – 0.009 inch to 0.25 inches Aspect ratio – within 1.3 to 2.5 Maximum weight – 3 ounces *Note: some booklet designs have shorter maximum lengths Booklets Mailpiece Design – Physical Standards

10. Paper: Generally booklet covers must be made with a minimum paper basis weight of 60-pounds book-grade or equivalent. Minimum basis weights are higher for some designs DMM 201 Exhibit 3.15.4 lists minimum paper weights by design DMM minimum paper basis weights are based on book-grade Booklets Mailpiece Design –Paper Requirements

11. Paper Conversion Example: Mailing Standard: Minimum Paper Weight is 60 lbs If the mailpiece cover is 55 lb newsprint that equals the minimum paper weight of 60 lbs book-grade. If the mailpiece cover is 50 lb newsprint that does not equal the minimum paper weight of 60 lbs book-grade. Booklets Mailpiece Design –Paper Requirements

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

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

14. Glue Spot: May be used in lieu of tabs Must be placed within ¾” of the open edges Must be at least 1” in diameter Booklets Mailpiece Design – Closure Method

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

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

17. Simple Spine - Wallet Style Saddle-stitched spine (two or more staples) on the bottom (longer) edge. 4" height only. Maximum Weight 2.5 ounces. 5.2'' to 8'' long 60-pound for cover and pages 70-pound cover with 50-pound pages Two 1.5'' or 2'' non-perforated tabs One tab on leading edge and one tab on trailing edge. Booklets up to 2 ounces: 1.5" tabs ---1-1/4" from bottom edge Over 2 ounces up to 2.5 ounces: 2" tabs -- 3/4" from bottom edge ±1/8" vertical tolerance for tab placement for both tab sizes Booklets Mailpiece Design

18. Folded Booklet (“Quarter-Fold”): Final fold on bottom (longer) edge; spine folded on leading edge Place two tabs on leading edge and one on trailing edge: Position lower leading tab 0.5 inch from bottom edge Position upper tabs 1 inch from top edge May use 40-pound; 50-pound paper recommended Final fold on the bottom (longer) edge, with the folded spine on the leading or trailing (shorter) edge 5” to 10.5” long 40-pound Three 1.5” non- perforated tabs Folded Booklet Two tabs on leading edge; one tab on trailing edge. Position lower leading tab 0.5 inch from the bottom edge. Position upper tabs 1 inch from the top edge. Booklets Mailpiece Design

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

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

21. Booklets Mailpiece Design Perfect Bound • Perfect bound or saddle stitched with a continuous glue line along the top open edge of the cover preferred, minimum 1” glue spots acceptable if placed within ¾” of right and left edges: • Must use 80-pound paper

22. Postponed proposed Folded Self-Mailer rule Established advisory team through MTAC leadership for further collaboration on mailpiece evaluation and testing Utilize mailer-supplied test material, in addition to USPS controlled test designs Target test completion by Fall 2009 Proposed rule in Winter 2009 -2010 What about Folded Self-Mailers?

23. WHO ARE MY RESOURCES? • Mailing Requirements • Business Mail Entry Units • Mailpiece Design Analyst • Mailing Standards Specialist

24. THE END RIGHT ON TARGET QUESTIONS?? QQQQ U.S.P.S.