Three preparation categories
USPS sorts letters and cards into three preparation categories that determine which prices apply:
- Machinable: meets size, shape, and weight standards and can run on USPS equipment. Eligible for presort prices.
- Nonmachinable: fails a machinability standard (see Why would a letter be nonmachinable); pays a surcharge and cannot claim automation prices.
- Automation: machinable AND carries a valid Intelligent Mail barcode with an address that meets quality standards. Earns the lowest per-piece prices.
What do I need to get automation prices?
Automation prices exist for letters, cards, and flats. The preparation details below describe letters and cards; flats have their own automation standards, including the top-half address rule in Where does the address go on a flat.
To claim automation prices a mailing must have: a correct, standardized, CASS-processed address on each piece; a valid Intelligent Mail barcode (see What is the Intelligent Mail barcode); Move Update compliance (see What is the Move Update requirement); and machinable pieces prepared to the required sort level. Missing any one drops the mailing to a higher price. See DMM 233 and 243.
How many pieces do I need for presort pricing?
- First-Class Mail presort: minimum 500 pieces.
- USPS Marketing Mail and Nonprofit: minimum 200 pieces or 50 pounds, whichever comes first.
Below these minimums, single-piece (retail) prices apply. See DMM 233 and 243.
What are the presort sort levels?
Deeper sortation earns lower postage because the mailer does more of the sorting work. From least to most granular, common letter presort levels are Mixed AADC, AADC, and 5-Digit. Flats use ADC and 5-Digit levels. The achievable levels depend on how the list densifies into ZIP areas; the software determines them at processing. Exact per-level rates are in Notice 123; the Postage Estimator shows what a given list qualifies for.
Density and carrier route
For saturation and high-density mailings, carrier-route and saturation prices can be lower still, but they require enough pieces per carrier route to qualify. Whether a list hits those densities is determined at processing. See DMM 243.
Why it matters
The gap between single-piece and automation 5-digit pricing is large across a full mailing. Preparing artwork to be machinable (right size, aspect ratio, barcode clear zone, address placement) and running a clean, CASS-processed, Move-Update-compliant list is what unlocks the lowest Notice 123 prices. Final qualification is confirmed at PostalOne acceptance.