On September 8th, new U.S. Postal Service regulations will take effect creating a new Booklet class of self-mailers. The regulations include new specifications for booklet size, paper weight and sealing options for machinable, automation letter-size booklets.
Industry Buzz
Before we get into the details of the changes, we want to highlight what we are hearing throughout the industry. First, once-standard 1" seals are replaced with 1.5" seals. This affects both how the piece is designed and the mechanics of setting the equipment. Second, the number of seals (see below) may require multiple passes, which affect both production times and labor costs. Third, from a practical standpoint no one will be using Mylar seals anymore. By not allowing perforations, plastic seals just won't open easily. To avoid pieces from being ripped or torn when opened, translucent or white paper seals will now become the new standard.
Below are the new Booklet class standards and specifications per the Domestic Mail Manual (DMM):
USPS Definition of Booklets
Booklets must have a bound edge. 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 an end 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 qualify for automation and
machinable prices if the final mailpiece remains nearly uniform in thickness.
Minimum and Maximum Dimensions
Height: 6 inches maximum, 3.5 inches minimum Length: 10.5 maximum, 5 inches minimum Thickness: 0.25 inch maximum, 0.009 inch minimum Weight: Not more than 3 ounces Aspect Ratio: Within 1.3 to 2.5
Design and Sealing
Tabs (or wafer seals), glue spots, glue lines and tape are acceptable sealing options. Placement varies based on the design of the booklet; the chart below breaks down the options:
Spine or final fold style |
Length |
Minimum cover stock |
Seal mailers with... |
Tab location |
 Spine or fold on the bottom (longer) edge |
5in. to 9in.
Over 9in. to 10.5 in. |
50lb
60lb |
Three 1.5in. non-perf tabs |
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. |
 Final fold on the bottom (longer) edge, with the folded spine on the leading or trailing (shorter) edge |
5in. to 10.5in. |
40lb |
Three 1.5in. non-perf tabs |
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. |
 Spine on the leading (shorter) edge |
5in. to 9in.
Over 9in. to 10.5 in. |
60lb
70lb |
Three 1.5in. non-perf tabs |
Two tabs on top edge; one tab on trailing edge. Position top tabs 1 inch from left and right edge. Position trailing tab in the middle. |
 Spine on bottom (longer) edge, nonperforated inner flap on top (upper) edge |
5in. to 9.5in. |
80lb |
Continuous glue line or glue spots |
Perfect bound or saddle stitched with a continuous glue line along flap preferred, minimum 1-inch glue spots acceptable if placed within ¾-inch of right and left edges. |
 Spine on bottom (longer) edge, cover extends no more than 1/2-inch beyond inner pages |
5in. to 9.5in. |
80lb |
Continuous glue line or glue spots |
Perfect bound or saddle stitched with a continuous glue line along 1/2-in. overhang preferred, minimum 1-inch glue spots acceptable if placed within ¾-inch of right and left edges. |
Planning Considerations
EZ-release hot melt adhesive is typically more economical than wafer sealing, resulting in lower costs and reduced turnaround times. If you plan to use glue to seal your self-mailing booklets, consult your bindery to determine if glue spots or a continuous glue line will work better for your project. As with any gluing application, test for proper adhesion on a printed sample prior to production. Ink and coating coverage, stock weight and finish and booklet bulk can all have an impact on adhesion quality. Also, some ink, coating and glue combinations may result in staining once the glue is rubbed away. If you plan to use tabs or wafer seals, be sure to keep copy and images away from the wafer seal placement area, especially if opaque paper seals are used. While translucent seals won't obscure printed information, USPS specifications prohibit their placement in the barcode clear zone. Let your bindery help you select the right wafer seal style for your application.
The Rickard Advantage:
Rickard Bindery is your headquarters for efficient booklet and self-mailer production. Our unparalleled combination of folding, saddle stitching, EZ-release and remoistenable gluing capabilities ensures fast turnaround on self-mailing booklet project runs in the millions.
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