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How should I package PLBs for mailing?

Once you have created your PLB, you will want to package it in a way that will help ensure that its components stay together and that it eventually returns safely to you. Expectations and requirements will vary, but here are some general guidelines:

Always refer to the Tracker host’s specifications for their requirements when preparing a Postal for mailing.

You can also refer to the Post Office for current guidelines for mailing packages or letters.

Important Note:If your envelope has postage stamps and weighs more than 10 oz or is thicker than 1/2", you can't put it in a collection box; you have to give it to an employee at a Post Office location.

Internal Packaging (applies to Standard and Heavy PLBs): The stamp should be contained within something that will absorb residue ink. This is often a piece of felt or cloth simply wrapped around the stamp or tied with a ribbon or string. Be aware that a string or band around a stamp can cause a divot in the carving. Others make or purchase decorative pouches for their stamps, while some incorporate the stamp holder into the logbook itself. The logbook and stamp (with its container) may then be put into a baggie. Write the name of the Letterbox, your name and address, and the AQ number on the bag on each baggie. This will help keep the contents together and identifies them if they get separated.

If you include additional items (explanation pages, CDs, DVDs, etc., in separate bags), all of these items should be placed within a larger overall bag. In these cases, it is a good idea to make a list of the contents and tape it to the plastic bag.

Internal Packaging (applies to Micro PLBs): Packaging of Micro PLBs is very important for meeting Post Office requirements. The entire finished piece needs to easily slide through a space/slot that is 1/4" wide. Items inside need to be spaced out and anchored in some way to avoid shifting. Example: if a logbook and stamp are free to move about they may end up on top of each other can cause the whole postal to get eaten by a hungry automated postal machine. The stamp needs to be thin enough to be flexible and not cause the entire Postal to be over 1/4" in thickness.
The logbook can be the same thickness and flexibility as the stamp, or it can be a folder that holds everything else in place for the recipients to stamp their sig stamps.

External Packaging (applies to Standard and Heavy PLBs): Boxes and Envelopes are intended to be reusable from stop to stop. The usual envelope size for Standard PLBs is 6x9, but this will vary according to the size of the PLB, Heavy PLBs can be any size and shape. The bubble mailer envelopes hold up longer under repeated use, and add a cushion of protection for the contents, so most people prefer them. When using bubble mailer envelopes, it is helpful to cover the areas that are likely to be used the most with clear packing tape. People who use paper envelopes which work well, but are less costly, often cover the entire surface of their envelopes with clear packing tape so they will be sturdier. Never cover postage stamps with tape as this will invalidate them.

The PLB's owner's return address should remain on the envelope/box throughout its travels. Do not cover the owner's return address when you are mailing PLBs that you have received. If you see that the owner's return address has been covered at some point or is missing, it is a nice idea to contact the owner privately and ask if they would like you to restore the proper address.

Most people write an abbreviated description of the box's title someplace on the outside of the envelope. This will help when mailing several at one time.

External Packaging (applies to Micro PLBs): Micro PLBs use a fresh (new) #10 regular business envelope at each stop. The envelope the Postal arrived in is not reused. Trying to create a reusable mailer for a Micro PLB (by covering with clear tape) causes problems as the automatic sorting equipment kicks them out when the printed barcode information gets smeared. This can delay delivery as these need to be hand sorted and require a non-machinable surcharge.

Most participants will include a set of return address labels to put in the upper left corner. They are either sticky labels, or a simple printed Word Doc of multiple address labels that can be cut apart and glued or taped on as needed. See General Guidelines for Addressing below.

Sealing Reusable Envelope (Standard and Heavy): Do not use the envelope's adhesive strip to seal the envelope. This damages the envelopes quite a bit, particularly with the bubble mailer envelopes. Instead, use clear packing tape to cover the adhesive strip so that it cannot be removed and also to seal the envelope. When you are repackaging a PLB that you have received, never reuse pre-existing tape, because it is likely to pop open in transit. Always use fresh tape! If possible, peel the tape to open the package. Try to avoid cutting the tape, but at times this is unavoidable.

General Guidelines--Addressing for Automation (Applies mostly to Micro PLBs): The Post Office uses automated equipment to facilitate speedy and cost effective handling of the US Mail (no comments please). In order for your mail to make the most efficient use of this system, it is best to use white envelopes or labels with black ink. Print carefully or type in all uppercase, use abbreviations where appropriate and no punctuation. Remember, the address needs to do the job of getting read by a machine, if a person needs to sort it out, it will take longer.

This is copied directly from USPS.com: Step 2: Address Your Mail
Print addresses neatly in capital letters.
Use a pen or permanent marker.
Do not use commas or periods.
Include the ZIP+4 Code whenever possible.

Security Precautions: Particularly since 9/11, the post office is much more concerned about matters relating to security. Just like you should not plant a letterbox that might be mistaken for a bomb, do not mail postals that might be mistaken for a bomb or weapon. Things that might cause a security scare can include (but are not limited to) not having enough postage, using only a person's trail name instead of their real name, well-worn packaging, and not using a proper return address label.