Table of Contents

3
Processing Categories  

The primary purpose of identifying a processing category is to place the mailpiece into the mail processing stream that will most effectively transport the mail. This ensures that your mailings will receive proper handling and expeditious delivery. In addition, the processing category of a mailpiece determines what types of automation discounts are available.

The size of a mailpiece may be determined by the required medium for a particular customer's message (such as a catalog). This can also work in reverse, that is, the desired postage rate can determine the medium. First, you choose the desired postal rate or preparation option, e.g., automation letters. Then, based on the requirements, the designer can "work backwards" to the required piece size.

Individual mailings need to be separated into one of the following five mail processing categories, based solely on the physical dimensions of the mailpiece:

 

This is a graphic of an open book. WHAT YOU WILL LEARN ABOUT USPS PROCESSING CATEGORIES

Upon completion of this module, you should be able to do the following:

USPS MAIL PROCESSING

The Postal Service processes mail by manual, mechanical, or automated operations.

If your presorted mail is not compatible with USPS automation requirements (such as a letter-size mailpiece with a pen enclosed), it has to be processed mechanically or manually. This is time-consuming and costly and will likely reduce the worksharing discounts you might otherwise be entitled to on mail entered at the Business Mail Entry Unit (BMEU).

The USPS sorts or "processes" mailpieces differently according to their size. The various sizes, or processing categories, of mailpieces are a reflection of the size limits of the sorting equipment or method used to process that particular type of mail. The type of equipment the Postal Service uses to process your mailpieces often determines your potential discounts.

AUTOMATED LETTER PROCESSING EQUIPMENT

The Postal Service processes and distributes mail through a variety of mechanized and automated equipment. The most efficient and accurate processing comes from the use of automated, high-speed, computerized mail sorting and processing equipment. The Postal Service uses two basic types of automated equipment to process letter-size mail: Optical Character Readers and Barcode Sorters.

Optical Character Reader (OCR)

An optical character reader (OCR) also known as Multiline Optical Character Reader (MLOCR) scans addresses on letter-size mail, determines the ZIP+4 code and the delivery point information, and converts that information into a POSTNET (Postal Numeric Encoding Technique) barcode. The OCR then prints a delivery-point barcode in the lower right portion (barcode clear zone) of the mailpiece. An initial sortation of the mailpiece by ZIP Code is then performed. OCRs read information printed in the address block.

OCRs verify address information against an internal database. After locating the address, the OCR must be able to see all elements clearly. This is why a complete address and "good" print quality are so important.

The OCR then does an initial sort of the mailpiece, based on the barcode. From that point on, the mailpiece is sorted by reading and interpreting the barcode using high-speed barcode sorters (BCSs). These machines are capable of reading, barcoding, and sorting mail at a rate of 36,000 pieces per hour or 10 pieces per second.

If you accurately barcode your letter-size mailpieces, they can skip the entire OCR process and go straight to a barcode sorter (BCS). It is mail in this category that the Postal Service has designated to receive the maximum postage discount.

Barcode Sorter (BCS)

A Postal Service barcode sorter (BCS) "reads" POSTNET barcodes on letter-size mailpieces and sorts the mail accordingly. These machines do not read addresses, so an incorrect barcode applied by a customer will cause the piece to be missorted. The BCS is capable of reading and sorting 36,000 pieces per hour, approximately 11 pieces per second.

A BCS can now find a barcode almost anywhere on the face of a letter-size mailpiece. This includes both in the address block area and barcode clear zone (defined later in this course). This allows mailers to use their addressing mechanisms to apply barcodes and qualify for lower rates and take advantage of faster, more efficient mail processing. The barcode must be printed within 4 inches of the bottom edge of the piece as part of the address block or within the barcode clear zone in the lower right corner.

The Postal Service offers voluntary certification for the computer systems and printers for POSTNET barcoding. The software used for ZIP+4 code, delivery point and carrier route matching is also certified. You can obtain a list of vendors offering this hardware and software from your local Postal Business Center or by visiting our website at http://www.usps.com.

When purchasing any ZIP+4 matching software, make certain that the product bears the Postal Service certification seal if you plan to claim automation discounts. The software must be Coding Accuracy Support System (CASS) certified. The Postal Service also offers voluntary hardware certification for barcode printing.

FLAT MAIL PROCESSING EQUIPMENT

At the present time, the Postal Service has two types of flat sorting equipment that are explained below. Flats cost the Postal Service more to process than letter mail. Because of this, the postage rates for flats are higher than the postage rates for letters.

AFSM 100

The AFSM 100 streamlines the flat mail processing operations and reduces manual processing. The AFSM 100 is capable of processing 20,000 flats per hour. It includes an optical character reader (OCR), barcode reader (BCR) and an online video coding system (VCS) for processing OCR rejects. It has three high speed feeders that are capable of feeding two flat mail pieces per second. The AFSM 100 has 253 buckets that have three pockets each. These 759 pockets are where the flat mail pieces are injected and then circulate around the chain-driven transport section (carousel) of the machine and fall into one of the 120 flat trays that serve as sortation bins for the machine. These 120 stackers have the capability of future expansion. The AFSM 100 is the Postal Service’s most efficient automated flats processor.

UFSM 1000

The UFSM 1000 is a flat sorting machine that has been retrofitted with automatic feeders, optical character readers and an upgraded control system. This machine processes oversized flat mail that in the past, would have to be worked manually. After the flat has been inducted into the machine, it is fed between two belts to its proper bin. The UFSM 1000 is capable of processing 10,000 flats per hour.

PARCEL SORTATION

The Postal Service began its automated parcel sortation efforts after the letter mail initiatives. New and more productive equipment continues to be deployed. The addition of the linear inline parcel sorter (LIPS) and the UFSM 1000 has enabled the Postal Service to automate the distribution of mailpieces previously sorted entirely by hand.

Two other systems remain the backbone of USPS automated parcel sortation efforts:

Small Parcel and Bundle Sorter (SPBS)

The Small Parcel and Bundle Sorter (SPBS) sorts small parcels, irregular parcel post and bundles of mail into as many as 100 separations. The SPBS is an operator-paced machine that sorts between 650 and 1000 pieces per induction station per hour. Mail is introduced through input hoppers, which feed induction station conveyors. The conveyors present parcels to the operators who key the mail pieces to three or five digit ZIP Code destinations. The mail pieces are then mechanically transported to the associated distribution bin. SPBS machines are typically used at processing and distribution centers (P&DCs) & bulk mail centers (BMCs) throughout the nation.

Large Parcel Sort System (LPSS)

The Large Parcel Sort System (LPSS) scans large packages and sorts packages based on their barcode. Packages are sorted through a quick array of machines equipped with sensors that carefully move the packages along, preventing them from being damaged.

Bulk Mail Center Parcel Barcode Sorting (PBCS) System

The Postal Service began deployment of the package barcode sorting (PBCS) system to all bulk mail center (BMC) parcel sorters in 1992. The system, which is integrated into the existing parcel sorter’s high speed inductions units, consists of an overhead omni directional scanner that reads mailer and USPS-applied barcodes. A system controller and a USPS-designed printer/applicator prints and applies barcoded labels on mail pieces without barcodes. The productivity inherent in this system has allowed the Postal Service to begin offering barcode discounts to mailers who apply 5-digit UPC barcodes to their machinable parcels.

Automated Package Processing System (APPS)

The Automated Package Processing System (APPS) is the Postal Service's next generation machine for sorting parcels and bundles of mail. The APPS will further automate package processing by providing greater processing capacity through automatic package induction, singulation, and address recognition.

he APPS utilizes an automated induction system with state-of-the-art recognition technology to maximize processing efficiency.  The camera based system captures images from multiple sides of the bundle for use with bar code reading (BCR) and optical character recognition (OCR) software.  Once the images are lifted, the mail piece is placed onto the carousel sorter awaiting resolution of the destination information.  Image clarity is essential for the successful performance of the automated recognition.  If the BCR and/or OCR is unable to resolve the destination information from the images, these same images will be sent to a remote encoding center (REC) for keying.  If the images at the REC are of insufficient quality, the piece will be rejected from the APPS and sent to a staffed semi-automatic induction station.  If the piece image is unable to be resolved at the semi-automatic induction station the mailpiece is then sent away from the APPS to a manual processing operation.

 

MAILABILITY

Mailpiece design and construction that conforms to Postal Service requirements reduces costs for you and the Postal Service. Proper design and construction of a mailpiece also ensures its mailability. Mailpieces not meeting required minimum criteria, or exceeding certain maximums, are nonmailable. As a reminder, nonmailable means that the piece, as designed, is prohibited from the mailstream. No fee, surcharge, or additional postage may make a nonmailable item mailable.

MINIMUM DIMENSIONS

Unless prepared as Customized MarketMail, all mailpieces that are 0.007" thick or less (except keys and identification devices) must be rectangular in shape.

MINIMUM DIMENSIONS

Height:  3 1/2 inches; Length: 5 inches

This graphic shows the minimum dimensions for mailing as described in the text.

Generally, the placement of the delivery address generally establishes which dimensions of the piece are the length and the height for determining mailability. The length is the dimension that is parallel to the address as read. The height is the dimension perpendicular to the length. For parcels, length is the distance of the longest dimension and girth is the distance around the thickest part.

This general rule does not apply to:

Improper placement of the address on a mailpiece may result in a failure to meet minimum size standards and can make the mailpiece nonmailable and prohibited from the mailstream.

The same size mailpiece, if under 1/4 inch in thickness, can be both mailable and nonmailable, depending upon the orientation of the delivery address. Be sure to take this into account when considering the layout of "pamphlet" style mailpieces.

NONMAILABLE       MAILABLE
(must be at least 5" long)

This graphic shows mailable and nonmailable mail

Rectangular In Shape

Rectangular in shape means that the opposite sides of a mailpiece must be equal in length and meet at right angles. Square mailpieces are mailable. The requirement to be rectangular does not exclude a square shape. However, because the minimum mailable size is 3 1/2 by 5 inches, the smallest size a square mailpiece could measure is 5 by 5 inches.

Rounded (finished) corners are permissible on letter-size card-type mailpieces or post cards made of cardstock that does not exceed a radius of 0.125 inch (1/8 inch). See Exhibit 1.1.1c.   DMM 601.1

First-Class Mail square mailpieces, not meeting aspect ratio, weighing 1 ounce or less are subject to the current applicable nonmachinable surcharge as specified in DMM 301.2.1c. Standard Mail square lettersize pieces, not meeting aspect ratio, weighing 3.3 ounce or less are subject to the nonmachinable letter rates as specified in DMM 243.1.5

Rectangular in shape does prohibit some creative designs for letters or cards such as those that are heart-shaped or designed with scalloped edges. These shapes cannot be processed through the automated equipment. However, the Postal Service realizes the need for diversity and has implemented Customized MarketMail for this purpose. After acceptance procedures, the Customized MarketMail bypasses all processing equipment. The customer is required to deposit (by transporting or by using Priority Mail or Express Mail dropship) the mail at the destination delivery unit. Please refer to Quick Service Guide 705a Customized MarketMail for further information.

Aspect Ratio

The aspect ratio of a mailpiece is its length divided by its height. For letter-size mail, this should be not less than 1.3 nor more than 2.5. Mailpieces outside this range can cause problems in the Postal Service's sorting equipment as they tend to tumble or jam during processing. Follow the instructions in the shaded area in the upper right corner of Notice 3A to determine whether a mailpiece meets the aspect ratio requirement.

NONMACHINABLE ASPECT RATIO: 1.25

This graphic shows the nonmachinable aspect ratio of one point twenty-five

5 divided by 4=1.25

MAXIMUM DIMENSIONS

To be mailable, no mailpiece may weigh more than 70 pounds or measure more than 108 inches in length and girth combined. Package Services Parcel Post only, however, may be up to 130 inches in combined length and girth. Length is the distance of the longest dimension and girth is the distance around the thickest part.

KEYS AND IDENTIFICATION DEVICES

Keys and identification devices are acceptable for mailing if they bear, or have securely attached, a company name and complete mailing address. The attachment must have instructions to return the item, and a statement guaranteeing the payment of postage due upon delivery. These items usually have instructions to the effect "If found, please drop in nearest mail box. Postage Guaranteed."

This service is available to all who wish to use it. No application is required. The items are self-identified and must bear the statement guaranteeing payment of postage. Postage is collected upon delivery in the same manner as postage due is collected for the return of other undeliverable or shortpaid items.

HOW TO MEASURE LENGTH AND GIRTH


           this graphic shows how to measure length and girth        Measure length

Measure girth


                                                              Measure length
                    Measure girth          This image shows how to measure length and girth


This image shows how to measure length and girth   Measure girth
          Measure length

 

LETTER-SIZE MAILPIECE DIMENSIONS

Once it is determined to be mailable, the Postal Service bases a mailpiece's processing category solely on its physical dimensions, not address orientation. Letter-size mail consists of those pieces with the following dimensions:

Letter-Size Mailpiece Dimensions

Dimension Minimum Maximum
Height 3-1/2 inches 6-1/8 inches
Length 5 inches 11-1/2 inches
Thickness 0.007 inch 1/4 inch

LETTER-SIZE DIMENSIONS

this graphic shows letter-size dimensions

For automation rate eligibility, mailpieces exceeding 4 1/4 inches by 6 inches must be a minimum of 0.009 inch thick (DMM 201.3.2). If the mailpiece exceeds any one of the maximum dimensions for letter-size mail, it enters the flat-size category (flats are covered next) as long as it does not exceed any maximum flat-size dimension.

Notice 3A, Letter-Size Mail Dimensional Standards Template, can be used to determine qualification for the letter-size processing category, as well as aspect ratio.

The placement of the address can cause a piece to be categorized as nonmailable or nonmachinable. Except for automation rate flat-size mail and parcels, the length is the dimension that is parallel to the delivery address as read, and the height is perpendicular to the length.

Nonmachinable Mail

The physical dimensions or placement of the address may subject a piece of mail to a nonmachinable surcharge. Nonmachinable mail may result in processing delays or damaged mail because the mail is not compatible with machine processing. For this reason, mailers are discouraged from designing nonmachinable mailpieces. The nonmachinable surcharge is explained in detail in Module 7.

ODD-SHAPED ITEMS IN ENVELOPES

Pens, bottle caps, and similar odd-shaped items are nonmachinable in letter-size envelopes and are subject to the nonmachinable surcharge.

STAMPED CARDS AND POSTCARDS

Stamped cards provided by the Postal Service and privately produced postcards are designed to be mailed as a subclass of First-Class Mail, the card rate. Postcards are not subject to the nonmachinable surcharge. The Standard Mail rate structure does not include a card rate. Generally, Standard Mail mailpieces that are a minimum of 3-1/2" high by 5" long and 0.007" thick up to 6-1/8" high by 11-1/2" long and 1/4" thick are eligible for a letter rate. Pieces exceeding 4-1/4” or 6” (or both) are required to be at least .009” thick to be machinable. Standard Mail mailpieces exceeding this height and/or length but not meeting the thickness requirement are subject to a nonmachinable surcharge as explained in Module 7.

Postcard Construction

Each card or double card claimed at the card rate, must be:

Cards must be constructed of unfolded and uncreased paper or cardstock that is uniformly thick. They must be of a lighter color that allows addresses and postmarks to be legible. In general, attachments are not allowed. Cards claimed at the card rate are not subject to the nonmachinable surcharge.

Postcard Layout

First-Class Mail postage rates for cards are lower than those for letters. To ensure that the Postal Service gains the projected savings in processing these smaller-sized mailpieces, there are additional restrictions on address placement and layout for cards claimed at presorted and automation card rates. The address side of a postcard must either be divided horizontally or vertically as explained below. Cards not designed as such are required to pay the First-Class Mail letter rates. All cards claimed at the automation rate must comply to the standards for automation-compatible mail in DMM 201.3 and 201.1.0.

Vertically Divided Postcards

This format allows dividing the address side of the card into a left side and a right side, with or without a vertical rule. The delivery address, postage and any Postal Service markings or endorsements must appear on the right side measuring 2-1/8” measured from the right edge of the card, top to bottom inclusive. Cards claimed at the presorted rate may have nondelivery address information extending into the right side only if placed above the delivery address. There must be 1/8” of clear space around the delivery address.

This is a picture of a vertically divided postcard with barcode that meets automation standards.

Horizontally Divided Postcards

This format allows dividing the address side of the card into an upper and a lower portion, with or without a horizontal rule. The delivery address, postage and any Postal marking or endorsement must appear completely within the portion containing the delivery address that must be 1-1/2 high measured from the top or bottom edge of the card, as applicable, right edge to left edge inclusive. As an alternative when the delivery address appears within the lower portion, it is permissible for the postage, return address, and any Postal marking or endorsement to appear in the upper portion. Cards claimed at the presorted rate may have nondelivery address information extending into the address side only if placed above the delivery address. There must be 1/8” of clear space around the delivery address.

This is a picture of a horizontally divided postcard with barcode that meets automation standards.

Double Postcards

A double card consists of two attached postcards (folded together), one of which is designed to be detached by the recipient and returned by mail as a single card. Double postcards are not sealed against inspection and are examined to ensure that the reply half does not include an additional message as the reply half may not convey a message to the original addressee or a statement of account. It is to be used for response purposes. They must be prepared so that the address on the reply half is on the inside when the double card is mailed. The first (outgoing) half of a double card must be detached when the reply half is mailed for return. Postage is charged only for the addressed half when originally mailed. The reply half need not bear postage when originally mailed, but it must bear postage at the applicable rate when returned. The reply half may be prepared as business reply, courtesy reply, metered reply or as a merchandise return service label. Plain stickers, seals or a single wire stitch (staple) may be used to fasten the open edge at the top or bottom once the card is folded. Sealing on the sides of the card is prohibited for purposes of inspection.

FLAT-SIZE MAILPIECE DIMENSIONS

By definition, a mailpiece is considered flat-size if it exceeds any one of the maximum dimensions for letter-size mail. This is assuming it does not exceed any maximum flat-size dimension.

A mailpiece must not exceed any of the maximum physical dimensions to be classified as a processing category. A mailpiece may appear to be a letter in two dimensions but will actually be considered a flat when the third dimension is found to exceed the letter-size maximum.

Flat-size mail consists of those pieces with the following dimensions:

                      or

                     or

 

Maximum Dimensions

Maximum length: 15 inches.
Maximum height: 12 inches.
Maximum thickness: 3/4 inch.

FLAT-SIZE DIMENSIONS

This graphic contains flat size dimensions as described above.

A flat-size mailpiece must exceed at least one of the letter-size maximums.

Finished Corners

Rounded (finished) corners are permissible on flat-size mailpieces that does not exceed a radius of 0.125 inch (1/8 inch). DMM 301.1.1.


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This is a graphic of a pencil. Exercise 3 - 1

Directions: Circle the best response or fill in the blank to answer the following questions. Check your answers when you have completed the exercise.

1.  All mailpieces, except for keys, identification devices and Customized MarketMail, that are __________ inch thick or less must be ______________ in shape and at least __________ inches high and __________ inches long.

2.  Except for automation flats, Customized MarketMail and parcels, the orientation of the ____________ address on a mailpiece determines the length and height.

3.  Square mailpieces are mailable.

a.  true
b.  false

4.  A letter-size mailpiece may be no more than __________ inches high or ___________ inches long or __________ inch thick.

5.  To determine the aspect ratio of a letter-size mailpiece, you:

a.  Multiply the length by the thickness.
b.  Divide the length by the height.
c.  Divide the height by the length.
d.  None of the above.

6.  Pens, bottle caps, and similar __________ - shaped items are mailable in letter-sized envelopes when the nonmachinable surcharge is paid.

7.  A mailpiece qualifying for postcard rates must be a single piece of cardstock no more than __________ inches high by __________ inches long.

8.  A qualifying double postcard is charged postage for both the addressed half and the reply half when originally mailed.

a.   true
b.   false

9.  A flat-size mailpiece may be no more than __________ inches long or __________ inches high or __________ inch thick.

10.  Placement of the delivery address establishes which dimension is the length and which is the height for determining mailability.

a.  true
b.  false

11. A mailpiece is 5 by 7 inches and 1/8 inch in thickness.

a.  letter-size
b.  flat-size
c.  neither

12. A mailpiece is 6 by 11 inches and 1/2 inch in thickness.

a.  letter-size
b.  flat-size
c.  neither

13. The aspect ratio of the mailpiece in question number 11, above, is:

a.  1
b.  1.5
c.  1.4
d.  1.9

14. For automation rates, a mailpiece exceeding 4 1/4 inches or 6 inches (or both) must be at least _______inches thick.

 

Answers to Exercise 3 - 1

1.  1/4, rectangular, 3 1/2, 5; only keys and identification devices are not subject to these minimum requirements. All other pieces not meeting these minimums are nonmailable.

2.  delivery; except in the instances mentioned in the question, the dimension of the mailpiece parallel to the read direction of the delivery address is the length, the opposite dimension is the height.

3.  a, true; a square is considered a rectangle and is mailable, assuming the minimum length, height, and thickness requirements for mailability are met.

4.  6 1/8, 11 1/2, 1/4; are the letter-size maximum dimensions. Pieces exceeding any one of these maximums are considered flats, so long as they do not exceed any flat-size maximum.

5.  b, divide the length by the height; the result of this calculation determines the aspect ratio. The aspect ratio of a letter-size mailpiece must fall between 1.3 to 2.5 (inclusive), otherwise the mailpiece is considered to be nonmachinable.

6.  odd; these items may now be mailed in letter-size envelopes at single-piece and Presorted First-Class and Standard Mail rates when the appropriate nonmachinable surcharge is paid at the time of mailing.

7.  4 1/4, 6; in addition, the piece must be no more than 0.016 inch in thickness.

8.  b, false; postage is charged only for the addressed half when originally mailed.

9.  15, 12, 3/4; these are the flat-size maximum dimensions.

10. a, true; the length is the dimension parallel to the address as read. The height is perpendicular to the address as read.

11. a, letter-size; this piece meets the minimum requirements for mailability and does not exceed any letter-size maximum.

12. b; flat-size; this mailpiece exceeds the letter-size maximum thickness of 1/4 inch,
but does not exceed any flat-size maximum.

13. c, 1.4; the length of this mailpiece divided by its height equals 1.4.

14. .009” - To qualify for automation rates, mailpieces exceeding 4 1/4 inches or 6 inches (or both) must be a minimum of .009 inches thick.

PARCELS

Mailpieces that are neither letter nor flat-sized (except for some qualifying automation flat-size pieces) are "parcels." They may be either machinable, irregular, or outside parcels, based on their characteristics.

The contents of a parcel will frequently determine its overall size and shape. Therefore, it may be difficult or perhaps impossible to alter the dimensions of a parcel to comply with specific criteria for mechanized processing. At the very least, if possible, you should make changes to avoid the "balloon" rate, and the nonmachinable surcharge (covered later in this section).

Even without altering the basic size, shape, or weight, there are some things you can do to enhance the processing and delivery of your parcel. Proper and legible addressing and avoiding some of the more negative characteristics of "outside" parcels can go
a long way to ensuring efficient delivery.

MACHINABLE PARCELS

Machinable parcels are those articles that can be processed by parcel sorting machines deployed in the Postal Service's bulk mail centers (BMCs). Parcel sorting machines are large machines with an input station controlled by a computer, which mechanically sorts and distributes parcels. Machinable parcels include mailpieces that meet the minimum and maximum criteria listed below and do not have any characteristics that would make them flat-size mail, irregular parcels, or outside parcels.

Machinable Parcel Dimensions

Machinable parcels consist of those pieces that are rectangular and within the dimensions listed in DMM 401.1.5:

Machinable Parcel Dimensions

Dimension Minimum Maximum
Height 3 inches 17 inches
Length 6 inches 34 inches
Thickness 1/4 inch 17 inches
Weight 6 ounces1 35 pounds2

1. 3.5 ounces for lightweight parcels prepared under DMM 401.1.5.2.
2. For books or other printed matter, the maximum weight is 25 pounds.

Soft goods wrapped in paper or plastic bags, and enveloped printed matter weighing up to 5 pounds, are machinable only if all applicable packaging standards in DMM 601.3.5 are met.

MACHINABLE PARCEL DIMENSIONS

Maximum
This graphic shows maximum and minimum machinable parcel dimensions.

Note: A mailpiece measuring exactly 1/4" thick must be 3 1/2" high.

This envelope graphic represents specific design tips.  Only machinable parcels qualify for the USPS parcel barcode discounts.

 

Additional Design Guidelines for Machinable Parcels:

Other Machinable Parcels

Some parcels that do not meet all the general criteria for machinable parcels may be successfully processed by bulk mail center (BMC) parcel sorting equipment. A BMC plant manager may authorize a mailer to enter such parcels as machinable parcels rather than irregular parcels, if the parcels are properly labeled, entered at a Post Office within the service area of the authorizing BMC, and are destined for delivery within the same BMC service area.

IRREGULAR PARCELS

Irregular parcels are those parcels that, because of size or weight, cannot be processed by bulk mail center (BMC) parcel sorting machines. Irregular parcels are pieces that do not meet the criteria for machinable parcels. This includes mailpieces with any of the following characteristics:

OUTSIDE PARCELS

Outside parcels are those parcels that, because of their size, shape, density, container, or nature of contents, cannot be processed in postal sacks. Outside parcels include any of the following items:

or

NONMACHINABLE SURCHARGE

Nonmachinable mailpieces mailed at the inter-BMC/ASF Parcel Post, intra-BMC/ASF Parcel Post, DSCF Parcel Select, and DMBC Parcel Select rates may be subject to a nonmachinable surcharge in addition to normal postage. The surcharge applies to all the items previously listed as outside parcels with the following additions:

If a mailer pays the special handling fee (covered in module ten, Extra Services), then the nonmachinable surcharge is waived.

BALLOON RATE

Any Parcel Post or Priority Mail piece weighing less than 20 pounds and measuring more than 84 inches in length and girth (up to 108 inches) is charged the applicable 20 pound rate, regardless of weight. Depending on their characteristics, Parcel Post pieces subject to this balloon rate may also be charged a nonmachinable surcharge if they have any of the characteristics in DMM 101.7.1.

OVERSIZED RATE

Only Parcel Post mailpieces may exceed the normal 108 inch length and girth maximums. Parcel Post mailpieces may measure up to 130 inches in combined length and girth. Parcel Post mailpieces exceeding 108 inches in length and girth are charged a special oversized rate.

The Parcel Post nonmachinable surcharge does not apply to pieces mailed at the oversized rate.

DIMENSIONAL WEIGHT

Postage for parcels addressed for delivery to Zones 5-8 and exceeding 1 cubic foot (1,728 cubic inches) is based on the actual weight or the dimensional weight (as calculated in DMM 123.1.4.1 or 1.4.2 ), whichever is greater.

  1. Follow these steps to determine the dimensional weight for a rectangular parcel:
    a. Measure the length, width, and height in inches. Round off (see DMM 604.7.0 ) each measurement to the nearest whole inch.
    b. Multiply the length by the width by the height.
    c. If the result exceeds 1,728 cubic inches, divide the result by 194 and round up (see DMM 604.7.0 ) to the next whole number to determine the dimensional weight in pounds.
  2. Follow these steps to determine the dimensional weight for a nonrectangular parcel:
    a. Measure the length, width, and height in inches at their extreme dimensions. Round off (see DMM 604.7.0 ) each measurement to the nearest whole inch.
    b. Multiply the length by the width by the height.
    c. Multiply the result by an adjustment factor of 0.785.
    d. If the final result exceeds 1,728 cubic inches, divide the result by 194 and round up (see DMM 604.7.0 ) to the next whole number to determine the dimensional weight in pounds.
    e. If the dimensional weight exceeds 70 pounds, the parcel pays the 70-pound rate. 

SUMMARY

The correct classification of your mailpiece's processing category is crucial. The processing category often determines (and limits) the rates, discounts, and preparation options for which your mailpiece will qualify.

For instance, not all flat-size pieces will qualify for Standard Mail ECR preparation discounts. Letter-size mailpieces that do not meet the aspect ratio requirements do not qualify for automation rates.

In certain cases, you may need to know the intended postal discounted rate before you can design the piece or package. Failure to take processing category into account before, during, and sometimes after, the design stage can lead to delays and potentially higher rates during the postal acceptance and verification process at the business mail entry unit (BMEU).

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This is a graphic of a pencil. Exercise 3 - 2

Directions: Circle the best response or fill in the blank to answer the following questions. Check your answers when you have completed the exercise.

1. The maximum height and thickness for a machinable parcel is:

a.  1/4 inch
b.  11-1/2 inches
c.  15 inches
d.  17 inches

2. The Postal Service offers a discount for machinable parcels with the appropriate mailer applied ____________.

3. A parcel is categorized as an irregular parcel if its weight is less than:

a.  6 ounces
b.  8 ounces
c.  11 ounces
d.  25 pounds

4. Rolls and tubes up to 26 inches long are:

a.  machinable parcels
b.  irregular parcels
c.  outside parcels
d.  nonmailable

5. Metal boxes, wooden boxes, and metal-banded parcels are considered:

a.  machinable parcels
b.  irregular parcels
c.  outside parcels
d.  nonmailable

6. A parcel containing books or other printed matter is categorized as an outside parcel if its weight is more than:

a.  1 pound
b.  10 pounds
c.  25 pounds
d.  35 pounds

7. Parcel Post and Priority Mail pieces weighing less than __________ pounds and measuring over __________ inches combined length and girth are charged the applicable __________ pound rate.

Answers to Exercise 3 - 2

1. d, 17 inches; the maximum height and thickness for a machinable parcel is 17 inches. The maximum length is twice that; 34 inches.

2. barcode; discounts are available for barcoded parcels.

3. a, 6 ounces.

4. b, irregular parcels; rolls and tubes are not machinable on USPS parcel sorters. Rolls and tubes greater than 26 inches in length are outside parcels.

5. c, outside parcels; while mailable, these types of parcels are never machinable and
are subject to the nonmachinable surcharge.

6. c, 25 pounds; printed matter is typically a high-density parcel, hence the lower
weight limit.

7. 15, 84, 15; referred to as a "balloon" rate. This regulation ensures that the postage charged for this type of piece covers the cost of handling.

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