Polywrap and Polywrap Manufacturers

Polywrap is one kind of mailing wrapper, the cover that encloses a mailpiece, alongside envelopes and sleeves.5Publication 32: Glossary of Postal Termspage 125“An envelope, sleeve, partial wrapper, or polywrap used to enclose a mailpiece.”USPS original Polywrapping is an automated process: polythene feeds from reels under and around the pieces, the edges are heat-sealed, and the top and bottom are crop-sealed.1Publication 32: Glossary of Postal Termspage 165“(2) To enclose mailpieces with an automated process in which polythene is fed from reels under and around the pieces. The two edges are brought together and heat-sealed, and the top and bottom edges are crop-sealed to create the container.”USPS original

USPS tests polywrap film because polywrapped flats run through its automated sorting operations.3Test Procedures for Automatable Polywrap Filmpage 1“This specification covers the procedures required to test polywrap film used to enclose flat mail pieces for U.S. Postal Service automated sorting operations.”USPS original Film that fails the tests is unacceptable for USPS automated processing.3Test Procedures for Automatable Polywrap Filmpage 1“Materials that do not meet all of the requirements here are unacceptable for Postal Service automated processing.”USPS original In 2006, USPS studied polywrap films for compatibility with the Flats Sequencing System, a two-pass machine that sorts flats into delivery order.4PostalPro: Polywrap and Polywrap Manufacturers“In 2006, the USPS conducted a thorough study of automatable polywrap films to ensure compatability of automation flats with flats sequencing systems (FSS) and stand alone mail prep (SAMP) according to standards AFSM 100 and UFSM 1000.”USPS original6Publication 32: Glossary of Postal Termspage 89“A two-pass flats sorting machine that automates the sorting of flat-sized mail into precise delivery order by internally refeeding first-pass mail for sorting on the second pass.”USPS original The study also covered stand alone mail preparation, the manual operation that goes with that machine.4PostalPro: Polywrap and Polywrap Manufacturers“In 2006, the USPS conducted a thorough study of automatable polywrap films to ensure compatability of automation flats with flats sequencing systems (FSS) and stand alone mail prep (SAMP) according to standards AFSM 100 and UFSM 1000.”USPS original7Publication 32: Glossary of Postal Termspage 212“A manual mail preparation operation associated with the Flats Sequencing System.”USPS original It followed the standards for two flat sorting machines, the AFSM 100 and the UFSM 1000.4PostalPro: Polywrap and Polywrap Manufacturers“In 2006, the USPS conducted a thorough study of automatable polywrap films to ensure compatability of automation flats with flats sequencing systems (FSS) and stand alone mail prep (SAMP) according to standards AFSM 100 and UFSM 1000.”USPS original8Publication 32: Glossary of Postal TermsPDF page 24“A fully automated machine that processes flatsize mail.”USPS original9Publication 32: Glossary of Postal TermsPDF page 232“A flat-sorting machine that can handle pieces beyond the size range of the Automated Flats Sorting Machine (AFSM) 100.”USPS original

USPS-T-3204, Test Procedures for Automatable Polywrap Film, is the USPS specification for testing polywrap film.3Test Procedures for Automatable Polywrap Filmpage 1“This specification covers the procedures required to test polywrap film used to enclose flat mail pieces for U.S. Postal Service automated sorting operations.”USPS original4PostalPro: Polywrap and Polywrap Manufacturers“USPS-T-3204, "Test Procedures for Automatable Polywrap Film", describes exact test procedures and acceptable values for the new polywrap film characteristics for polywrap to be used on mailings of automation-rate flat-size mailpieces as of August 8, 2011.”USPS original It gives the exact test procedures and passing values for polywrap on automation-rate flats mailed from August 8, 2011.4PostalPro: Polywrap and Polywrap Manufacturers“USPS-T-3204, "Test Procedures for Automatable Polywrap Film", describes exact test procedures and acceptable values for the new polywrap film characteristics for polywrap to be used on mailings of automation-rate flat-size mailpieces as of August 8, 2011.”USPS original It also lists laboratories experienced in the tests.4PostalPro: Polywrap and Polywrap Manufacturers“It also provides a list of testing laboratories that have experience in conducting these tests.”USPS original Manufacturers and mailers of flat-size mail must comply with it.4PostalPro: Polywrap and Polywrap Manufacturers“Manufacturers and mailers of flat-size mail must comply with USPS-T-3204, which went into effect February 4, 2007.”USPS original The Polywrap Manufacturer List names the manufacturers and distributors of polywrap approved for automation-rate flats.4PostalPro: Polywrap and Polywrap Manufacturers“The Polywrap Manufacturers link is a downloadable document which lists polywrap manufacturers and distributors of polywrap approved for use on automation rate flat-size mailpieces in compliance with DMM standards effective February 1, 2007.”USPS original

The laboratory mails copies of the report to USPS and to the manufacturer, and keeps the original at least 2 years.11Test Procedures for Automatable Polywrap Filmpage 15“Mail copies to the Postal Service address in section 2.2 and the material manufacturer. Archive the original for at least 2 years.”USPS original Manufacturers, distributors and Mailpiece Design Analysts should send USPS a Certificate of Conformance, with the laboratory's test results when available.4PostalPro: Polywrap and Polywrap Manufacturers“Manufacturers, Distributors, and Mailpiece Design Analysts (MDAs) should mail Certificates of Conformance, including, if available, Independent Laboratory Conformance Test Results, to: Product Classification, 475 L'Enfant Plaza SW, RM 4446, Washington DC 20260-5015; or EMAIL to: Product Classification, ATTN: Polywrap Specialist, ProductClassification@usps.gov.”USPS original A Mailpiece Design Analyst is a USPS employee trained to answer questions about mailpiece design.12Mailer's Technical Advisory Committee - Best Practices for ACS™page 44“Postal employees specially trained to answer your questions regarding mail piece design.”USPS original

A film passes only when it meets all eight requirements.3Test Procedures for Automatable Polywrap Filmpage 1“Materials submitted for testing must meet or exceed all the requirements in 2.1.1 through 2.1.8.”USPS original Each USPS procedure but static charge supplements an ASTM test method and doesn't replace it.10Test Procedures for Automatable Polywrap Filmpage 2“This test procedure supplements, but does not replace, ASTM test method D1894.”USPS original

The static charge test copies, in a laboratory, the conditions polywrapped flats meet in automated mail processing.18Test Procedures for Automatable Polywrap Filmpage 10“This test procedure is designed to replicate the environmental, operational and mechanical conditions encountered by polywrapped flat mail during automated mail processing, in a controlled laboratory environment within the limitations of a laboratory environment.”USPS original

Revision F of USPS-T-3204, dated August 18, 2011, numbers the test procedures 3.1 through 3.7.19Test Procedures for Automatable Polywrap FilmPDF page 3“USPS-T-3204 - Test Procedures for Automatable Polywrap Film 2011-08-18 Rev F.doc”USPS original10Test Procedures for Automatable Polywrap Filmpage 2“Test submitted materials as described in 3.1 through 3.7.”USPS original The polywrap specifications in the Domestic Mail Manual, USPS's manual of mailing standards, cite those tests by their Revision D numbers.20Appendix D: Glossary of ACS™ Acronyms and TerminologyPDF page 5“The USPS manual that contains the standards governing domestic mail services, descriptions of the mail classes and services and conditions governing their uses, standards for price eligibility and mail preparation, and all postage prices and fees.”USPS original21Test Procedures for Automatable Polywrap FilmPDF page 2“Requirements identified in the DMM 4.5.1 Polywrap Specifications refer to specific sections for test methods in USPS-T-3204 – Test Procedures for Automatable Polywrap Film. … DMM USPS-T-3204 Rev D Section Number”USPS original A transmittal letter dated February 23, 2015 maps each Revision D number to its Revision F number.22Test Procedures for Automatable Polywrap FilmPDF page 1“USPS-T-3204 DMM Mapping - Transmittal Letter 2015-02-23”USPS original21Test Procedures for Automatable Polywrap FilmPDF page 2“Table 1 shows section numbers referenced in the DMM and the current section numbers in the most recent release for USPS-T-3204.”USPS original

The two secant modulus requirements say to test per 4.4.3Test Procedures for Automatable Polywrap Filmpage 1“The Secant Modulus must be greater than 50,000 psi in the transverse direction when tested per 4.4.”USPS original Section 4.4 covers corona-treated films, and the secant modulus procedure is section 3.4.2Test Procedures for Automatable Polywrap Filmpage 12“4.4 Corona Treated and Non-Treated Films”USPS original15Test Procedures for Automatable Polywrap Filmpage 6“3.4 1% Secant Modulus, Machine & Transverse Direction, ASTM D 882”USPS original

The manufacturer sends the laboratory a roll of film packaged one set way.2Test Procedures for Automatable Polywrap Filmpage 12“Polywrap manufacturers must submit polywrap film materials to the independent laboratory, packaged as follows.”USPS original

Corona-treated and untreated film of one formulation are submitted separately, and the laboratory runs every test on each.2Test Procedures for Automatable Polywrap Filmpage 12“Polywrap manufacturers must submit corona-treated and non-treated films of an individual formulation separately. … The laboratory must test each one separately with the complete battery of tests.”USPS original For a formulation made in several gauges, the manufacturer submits the thinnest.23Test Procedures for Automatable Polywrap Filmpage 13“For an individual film formulation manufactured in various gauges, manufacturers must submit the thinnest gauge film for testing.”USPS original When it passes, USPS lists the formulation for every thickness that meets the gauge requirement.23Test Procedures for Automatable Polywrap Filmpage 13“If the laboratory approves the thinnest film, the Postal Service will list the product as approved for all thicknesses that meet the gauge requirement in Section 2.1.6.”USPS original

USPS approves the independent laboratories that run the tests.23Test Procedures for Automatable Polywrap Filmpage 13“The Postal Service has approved the following independent testing laboratories to perform the tests in this specification as indicated.”USPS original Revision F names four for every test but static charge, and two for static charge.24Test Procedures for Automatable Polywrap Filmpage 14“Approved Laboratories - Requirements 2.1.1 through 2.1.7 … Approved Laboratories - Requirement 2.1.8”USPS original

USPS may audit the approved laboratories, and a USPS representative may watch testing during an audit.2Test Procedures for Automatable Polywrap Filmpage 12“The Postal Service may conduct periodic audits of the approved laboratories to insure they comply with the requirements of this specification. … A Postal Service representative may observe actual testing as part of an audit.”USPS original

A film that misses any specified value fails that test.3Test Procedures for Automatable Polywrap Filmpage 1“Failure to achieve the specified value listed for the test constitutes failure of the test.”USPS original Film not packaged the required way is unacceptable, and laboratories must not test it.2Test Procedures for Automatable Polywrap Filmpage 12“Film submitted in any other way is unacceptable. … Laboratories must not test film that is incorrectly packaged.”USPS original

Approval of film in one treatment condition doesn't imply approval of the other.2Test Procedures for Automatable Polywrap Filmpage 12“Approval of film in one condition in no way implies approval of the other.”USPS original

When the thinnest gauge fails, the manufacturer may submit thicker gauges until one passes.23Test Procedures for Automatable Polywrap Filmpage 13“Should the thinnest gauge fail testing, the manufacturer may submit successively thicker gauge film until successful test results are achieved.”USPS original USPS then lists only film at least as thick as the film that passed.23Test Procedures for Automatable Polywrap Filmpage 13“The Postal Service will only list film as approved that has a thickness equal to or greater than the successfully tested material.”USPS original

USPS's documents give each property a passing value but don't say how each property affects a sorting machine.

• Questions: Product Classification, ProductClassification@usps.gov.4PostalPro: Polywrap and Polywrap Manufacturers“For questions, please contact Product Classification by email at ProductClassification@usps.gov.”USPS original
• Certificates of Conformance: Product Classification, 475 L'Enfant Plaza SW, RM 4446, Washington DC 20260-5015, or ProductClassification@usps.gov, attention Polywrap Specialist.4PostalPro: Polywrap and Polywrap Manufacturers“Manufacturers, Distributors, and Mailpiece Design Analysts (MDAs) should mail Certificates of Conformance, including, if available, Independent Laboratory Conformance Test Results, to: Product Classification, 475 L'Enfant Plaza SW, RM 4446, Washington DC 20260-5015; or EMAIL to: Product Classification, ATTN: Polywrap Specialist, ProductClassification@usps.gov.”USPS original
• Test Results Reports from laboratories: Manager, Product Classification, U.S. Postal Service, 475 L'Enfant Plaza RM 4446, Washington DC 20260-5015.10Test Procedures for Automatable Polywrap Filmpage 2“The independent laboratory must mail completed Test Results Reports to the Postal Service representative at: Manager, Product Classification U.S. Postal Service 475 L'Enfant Plaza RM 4446 Washington DC 20260-5015”USPS original