Tom Kubinski
Printing Consultant
Direct: 612-278-1568
Fax: 612-334-5879
Cell: 612-760-3700
1109 Zane Avenue North
Minneapolis, MN. 55422
Phone: 612-375-1150
Fax: 612-334-5879
Toll Free: 1-800-230-2828

Branding - 22 Laws Of
Brand Warfare
Creative Coatings Techniques
Desktop Techniques
Digital / Variable Printing
Direct Mail Raise Response, Lower Costs
FSC Certification
For Direct Marketers
In House Mailing Capabilities
Ink Tour
Paper Mill Tour - Coated
Paper Mill Tour - Uncoated
Picking the Right Paper
PDF Formats
PDF Info & Quark vs. InDesign
PODi - Digital Print Success Story
Postal Changes, Mailing Requirements & Rates
Post it to the Web vs. Print
PURL - Avoid Dog House Campaign
QR Codes
Save Disk Space
Social Media -- The Basics
Social Media vs. Print
Top File Issues
UV Burn
Ways to Save Money
What Sets Sexton Apart?
Why Print in a Down Market?
Why Work With TK?

July 2010 TK's Korner
In-House Mailing Capabilities

10 WAYS Sexton Printing HELPS YOU
Maximize Efficiencies in Your Mailings:
  • Address Coding/Standardization/Delivery Point Validation (via CASS Certified Software)
  • Postal Presorting (via PAVE Certified Software to Maximize Postal Discounts)
  • Merge/Purge Services
  • N.C.O.A. Processing, ACS, Ancillary Service Endorsement
  • List Hygiene & Enhancement Services (i.e. Database Restructuring)
  • List Evaluation & Error Reports
  • Mailing Strategy Consultations
  • Single Source Control & Convenience
  • Dual Head Ink Jetting
  • Wafer Sealing

Meeting growing postal challenges while providing added control and convenience encouraged Sexton Printing to work closely with customers and the Post Office to develop effective mail distribution strategies aimed at getting materials delivered quickly and cost effectively.

Often the solution is not any single action, but a relentless pursuit of many small improvements along the process that make a big difference in costs, efficiencies and speed of delivery. Today the price of mailing magazines, journals, newsletters, catalogs and other printed materials can significantly affect an organization's bottom line.

As a result, you, the mailer, need to take a more comprehensive look at your objectives, considering everything from the date a printed piece needs to arrive at its final destination to mailing frequency and format issues.

Sexton Printing has been involved with mailing in many aspects for over 20 years. Our niche has always been and continues to be in publications, periodicals and direct mail.

We take a consultative and comprehensive approach TO EACH ONE OF OUR CUSTOMERS COMMUNICATION NEEDS with an emphasis on proper DESIGN FOR PRINTING, as well as MAILING REQUIREMENTS. In addition, we will evaluate the integrity of your list, checking for problems such as improper address formatting that can negatively affect mail processing.


  • An error report, which lists any addresses unsuccessfully, matched to the national database.
  • A list of addresses with invalid ZIP Codes.
  • Recommendations to help you improve your list preparation and achieve maximum list integrity.

One particular win-win situation, has been with a new client who had been doing the same mailing with another printing company for the previous two years. We suggested going to a heavier weight stock for a cost of $1000 more in paper that yielded a savings of $3000 in postage. Mail reclassification continues to reward automation compatible mail with discounts that are intended to compensate mailers for their preparation investments. (Mail not conforming to automation standards pays a premium or surcharge.)


  • In order to receive automation discounts for either First Class or Standard Mail, mail list must have been updated at least 95 days prior to mail date via NCOA, Address Requested, etc. (This regulation became live November 23, 2008.)
  • All ZIP Codes on mailings must be accurate to qualify for presort and/or automation discounts. Using PAVE (Presort, Accuracy, Validation and Evaluation) certified software is recommended.
  • Carrier Route mail must contain addresses that have been successfully matched to the most current USPS National database using CASS certified software. Coding must be performed within 90 days of the mail date.
  • For all other automated pieces, coding must be performed within six months, USPS approved documentation required in all cases.
  • Sexton CASS Codes/DPV Verification every mailing.


  • BRC / Postcards - Minimum 3.5x5 Maximum 4.25x6
    NOTE: What's important today in order to be machineable, is that the piece must be 7pt thick up to 4.25x6 or 9pt for sizes. Otherwise, you will lose automation discounts and pay a surcharge. Some stock will satisfy this requirement with 80lb stock while others will need to be heavier.
    Please make sure to double-check this!
  • Letter - Minimum 3.5x5 Maximum 6.125x11.5
    i.e. a 6x9 postcard falls into the Letter category.
    NOTE: The piece must meet the aspect ratio=relationship between the height and width to be machinable. Weight is a factor and depends on the specific postal classification.
  • Flat - Height- minimum=5" maximum=12"Length- minimum=6" maximum=15"
    NOTE: A design must is a particular orientation between final folded/bound edge and any intermediate folded/bound edge. Thickness no more than 3/4" thick. Weight for 1st class= 13 oz max, Periodicals= 20 oz max, Standard= less than 16 oz, Bound Printed Matter= 20 oz max.

STILL CONFUSED? DON'T WORRY... Sexton Printing offers complete in-house mailing services, and we're in compliance with the rules and regulations of reclassification.

Most important, we're fully committed to helping your organization develop an effective strategy to reduce mailing costs and speed delivery. We'll maximize your presort discounts through our PAVE and CASS certified software, then go several steps beyond to ensure you gain all the postal advantages possible.

When sending files to Sexton Printing via email, address them to Please be sure to include the following for faster and more accurate processing:

  • Name of each file
  • Number of records for each file
  • Specify the Sexton job number that has been assigned to your project (if applicable)
  • Send all files together at one time

NOTE: We do have a processing form that asks for more in-depth instructions for those projects that you feel needs to be further detailed.

I have included below some scanned charts of various envelopes along with their names, sizes etc. This may assist you with future projects and the inserted material sizing.

Click for larger version

Click for larger version

Click for larger version

Other issues of TK's Korners that may be of interest to you:

Hope this helps and stay tuned for the next issue of TK's Korner. You never know what might be covered!

If you have a production issue not discussed above that you would like me to address, or a project that needs to be looked at, please give me a call or send me an email. I will do whatever it takes to ensure you get the best value for every marketing dollar invested.

You can also check out my profile, join my network and view more client comments on LinkedIn at:

Referrals are greatly appreciated, if you know someone I could help, or who might like to receive TK's Korner, please let me know.

Take care and have a great day!

Tom Kubinski, Printing Consultant

Printing Consultant Who Helps You Make Good Impressions
Direct: 612-278-1568
Cell: 612-760-3700

TK Out Standing in his Field

(PS: If you'd like, Go to and sign up for the Sexton E Trends, a FREE e message service offering print production tips and industry trends designed to make your job easier and your production workflow more efficient.)

Make sure to check out other issues of TK's Korner!

Selected portions reprinted in Print & Media Buyer, a national magazine for the print industry (Search for Tom Kubinski).

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