USPS’s new tabbing requirements that went into effect in September can impact both the design and preparation of booklets.

The postal service defines a booklet as a letter-sized mail piece consisting of multiple sheets fastened together with a bound edge. Methods of binding include saddle-stitching, perfect binding, and press-gluing. Large bound booklets may be folded to meet the letter size requirements as long as they remain uniformly thick. The spine or final fold must be either at the bottom or the right edge when reading the delivery address.

Larger Tabs: A larger tab, 1.5" in diameter (compared to 1” tabs previously required) must be applied to the left and right edges of the booklet. Perforated tabs are no longer acceptable. In most cases, booklets will need to have three 1 ½” tabs. The USPS recommends two-inch tabs for larger or heavier booklets.

Smaller Booklets: Maximum height for machinable and automated booklets is now six inches. The maximum length can vary between 9 and 10 ½ inches, based on the design. Minimum thickness is .009, maximum is .25 inches. Maximum weight for a booklet is still 3 ounces.

If a booklet does not comply with these requirements, it is considered Non-machinable. In addition to paying non-machinable rates, these pieces are subject to a surcharge of 10 to 30 cents per piece, depending on class and sort level.

While these changes effect only booklets, the USPS is interested in revising specifications for all letter-sized self-mailers. Leading and trailing edge tabbing for all self-mailers may be required in the near future.