New postal standards have recently gone into effect that pertain to letter sized booklets. Booklets are mail pieces with a bound edge and include sheets fastened with at least two staples in the manufacturing fold (saddle-stitched), perfect bound, pressed-glued or joined together by another binding method that is automation-compatible and produces an end where pages are attached. Booklets are generally open on three sides before sealing, like a book.

Effective 9/8/09 new standards for letter sized booklets:
Design Prep
Stock Weight

The Post Office will implement new standards for design and sealing of letter size booklets. Following is a brief outline of changes:

Oblong booklets must be prepared with the spine on the leading edge.
Booklets with a spine on the trailing edge are non-machineable (10¢ - 30¢ more per piece).
Paper weight has increased based on design. Size is also adjusted.
Tab size and required location has been amended.
No perforated tabs are allowed.

These changes are a result of letter booklets not processing well through letter sorting machines. Letter booklet mailers tend to double feed or jam and perforated tabs can burst open during the high speed sorting process.

Maximum weight for machineable and automation letters and cards:
Machineable enveloped letters and cards - 3.3 ounces.
Automation enveloped letters and cards - 3.5 ounces.
Booklets and folded mailers - if over 3 ounces - must be in an envelope.
Additional physical standards:
Thickness: No more than ¼" or less than .009
Weight: No more than 3 ounces
Aspect ratio: Between 1.3 - 2.5
Contact us any time if you have additional questions. Foster Printing Service, 4295 Ohio Street, Michigan City, IN 46360. ph: 800.382.0808 2009