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ALR – Automation Letter Rate, USPS Case Number 91355

USPS Ruling Specifications:

    • Height between 4” – 6”
    • Length between 8” – 10.5”
    • 11/16” paper strip pre-affixed to address panel side of EnvyPak

– Paper strip runs flush with the bottom and along the entire length of EnvyPak

– EnvyPak affixes inline as the envelope is manufactured

    • Requires EnvyPak Smooth Anti-Reflective Polypropylene on address panel side only

– Address and IMB can be printed on the insert to show through the anti-reflective polypropylene

    • EnvyPak that is less than 6” tall – paper strip must be on large web
    • No ancillary endorsements
    • If mailed 1st Class, STID (Service Type Identifier) must be coded to waste (260 or 270)
    • Recommended minimum weight of insert = 80# cover
    • Clear gap requirements

– Option 1: Printed Side Seam (print over top of weld) – Maximum clear gap between the inside of side seam and the edge of insert = 0.2”

– Option 2: Clear Side Seam (no print on weld) – Envelope printed on one side to prevent a clear gap. NO clear gap is allowed.

ALR (Automation Letter Rate) Print Requirements:

USPS requires print on the leading and trailing edges of the envelope to trigger sorting sensors.


Edges can be printed on either or both sides of the envelope.

As the insert shifts from left to right the print must prevent a clear gap from occurring. A clear gap occurs when one can see through one side of the envelope and out the other.

Any print that prevents a clear gap can be compliant. Contact your sales representative for more creative approaches to meeting USPS requirements.

Standard EnvyPak envelopes often fall under DMM poly wrap guidelines. The material (not the envelope) is approved as a poly wrap.

EnvyPak ALR (automation letter) envelope guidelines do not fall within the DMM. DMM section 201.2.1 states “a letter-size piece is nonmachinable if it has an exterior surface that is not made of paper.” USPS issued an EnvyPak ALR-specific approval letter which overrides 201.2.1. The approval letter and a sample piece MUST be presented to Business Mail Entry (BME) acceptance personnel to pre-verify and dropmail.

Our products are specifically designed to be either manually or machine inserted and are regularly used on automatic insertion equipment at leading mail houses. Machines include Pitney Bowes Flowmaster, Bowe Bell-Howell Mailmaster as well as custom-made machines.

USPS Automation Approved Glue Seal Specs – USPS Case Number 91004

Option One: (5) 1” glue lines equally distributed along the length of the flap ending within .25” of the leading edge, trailing edge, and bottom edge of the

glue lines

Option Two: (1) continuous glue line within .25” of the leading edge, trailing edge, and bottom edge of the flap

Glue sealed mail pieces that do not meet the above specifications will not qualify for automation letter postage

USPS Approved Wafer Seal Specs – USPS Case Number 91355 – Revision of 6/3/22

Additionally, mailpieces that weigh one ounce or less, are permitted to have the flap secured with three one-inch wafer seals made of no less than 2.0 mil thick clear polypropylene.

The wafers must be placed as follows:

one wafer no less than 0.25” away from the left edge of the envelope, one wafer in the center of the flap, and one wafer no less than 0.25” away from the right edge

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