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Tips To Successful Direct Mail Production

Is the indicia correct?

  • Correct verbiage (see samples below)

Presorted Standard

Presorted First Class

Nonprofit Standard

Bound Printed Matter

Company Permit
  • Must be parallel to address block, no smaller than 8 point type


Is the piece going to have a live stamp, metered or a company permit?
  • If stamped or company permit - a full return address must be on the front or back of piece
  • In order to avoid mailing delays, provide mailing house with postage in advance. If a customer is using their own permit, make sure money is deposited in advance and provide mail house with a receipt or date of deposit
Does the organization have Non-Profit Status?
  • If the Organization has non-profit status at the post office of entry, all pieces must bear the exact name and address of the owner of non-profit status. Acronyms and abbreviations are NOT accepted by the post office.
Is the ancillary correct?
  • Correct verbiage (see below)
    • "Address Service Requested"
    • "Return Service Requested"
    • "Change Service Requested"
    • "Forwarding Service Requested"
  • Must be in one of four places
    • Directly below return address
    • Directly above delivery address
    • Directly left of the postage area and below any rate marking
    • Directly below postage area and below any rate marking
      • No smaller than 8 point type
      • 1/4 inch clearance around ancillary endorsement
Is the piece a letter or a flat?
  • The difference in postage between a letter and a flat can be close to $0.08 per piece. (Carrier route rates are the same for both letters and flats)
  • Letter
    • Minimum 3 ½" high, 5" long and 0.007" thick*
      • If thE length is over 7", the required thickness is 0.009"
    • Maximum 6 1/8" high, 11 1/2" long and 1/4" thick
  • Flat
    • Minimum 6 1/8" high, 11-1/2"long or ¼ " thick
    • Maximum 11 ¾" high, 14" long or ¾" thick
Does the piece have a varnish?
  • If so, a 4" x 2" window must be dropped for the address panel
  • If you are unsure, take a felt tip pen and test the piece for smearing
Does the piece meet the aspect ratio requirements for automation?
  • Aspect ratio= length/height
    • 1.3 >= aspect ratio <= 2.5
    • Length is determined by address location (parallel)
Are you taking advantage of automation (bar coding) postage discounts?
  • Bar coding letter size self mailers - if an open edge is on the bottom (folded edge on top), 2 wafer seals are required on the bottom panel (each being one inch from each edge); if the open edge is on top (folded edge on bottom), one wafer seal is required in the middle of the top panel
Does the address panel meet barcode requirements?
  • At least 4" x 2" window or panel
  • 1/8" clearance from any copy or window
  • At least 50% reflection
    Are you taking advantage of sectional center facility discounts (SCF) or bulk mail center discounts (BMC)?

  • All 453xx, 454xx, & 455xx zip codes dropped at the Dayton main bulk unit qualify for additional discounts. If practical, specific zip codes that qualify for scf discounts can be delivered to the appropriate bulk mail center (BMC), sectional facility center (SCF), or destination delivery unit (DDU)
  • On average, the savings are approximately $27/M in savings for SCF entry and $22/M in savings for BMC entry
Is there inserting involved in the mailing?
  • Give the design/art department the machine specifications before the job is designed; check specifications before the piece goes to print
  • Standard inserters require "booklet" (open flap on top) envelopes as opposed to "catalog" (open flap on side) envelopes
  • When ordering envelopes, specify that the envelopes must be machineable
  • Most invitation style envelopes (deep square flaps) are not machineable, check with your mail house
  • Open edges (e.g. "z-fold"): many inserters are unable to feed open edge material without special equipment. Check with your mail house.
  • Stapled pieces are not machineable
  • Clearance: allow at least ½ inch clearance on the inside width of the envelope (1/4 inch on each side), more clearance is better if multiple or thick pieces are to be inserted. Allow at least 1/8 inch clearance on top for flapping & sealing
    • Use this formula:
      • Length of enclosure + ½ " + thickness of envelope = length of envelope
      • Width of enclosure + ¼ " = width of envelope
  • Standard envelope sizes:
    • #6 ¼: 3 ½ x 6
    • #6 ¾: .3 ¾ x 6 ½
    • #7: 3 ¾ x 6 ¾
    • #7 ¾: 3 7/8 x 7 ½
    • Data card: 3 5/8 x 8 5/8
    • Check: 3 5/8 x 8 5/8
    • #9: 3 7/8 x 8 7/8
    • #10: 4 1/8 x 9 ½
    • #10 ½: 4 ½ x 9 ½
    • #11: 4 ½ x 10 3/8
    • #12: 4 ¾ x 11
    • #14: 5 x 11 ½
    • #16: 6 x 12
Printing
  • Before printing unusual, irregular pieces, have your mail house or post office approve the pieces, or at least give a determination on the class of postage, the cost per piece and any other pertinent mailing information. If there is a problem with the design, it is better to catch it early in the design process.
  • Request the printer to furnish packing lists with a description of each piece and quantities for each piece so that the mail house is aware of stock on hand. Shortage of materials may result in costly delays and additional set up charges.
  • Allow stock overage for set up and spoilage during mail processing, 3% - 5% on short runs. Consult with mail house on large runs.
Mailing dates
  • Get realistic production schedules and capabilities from the mail house in advance. On many mailings, production can't begin until all materials have been received. On time - sensitive mailings, it may be advisable to write a contract on the services to be performed and the time frame required, as well as verifying the quotation or estimate.
Mailing lists
  • If you can furnish your mailing lists/database electronically, most mailing houses can run the data through various software programs to:
    • Eliminate duplicates, select one per household, standardization of addresses
    • NCOA updates (national change of address)
    • Cass certify - (coding accuracy support system)
    • Append a Postnet Barcode and sort for optimal postage discounts
    • Zip selections
    • Prepare for ink jet or laser output
    • Append a Planet Code for tracking pieces through the mail stream