Scuff and burn marks on mailpieces: what’s causing it and how to protect your mail
If you’ve noticed scuff or burn marks on postcards and printed mail in your mailbox, you’re not alone. In the last several weeks, we’ve had an uptick in reports of mail being damaged this way during postal processing and delivery. We asked the Postal Service about it and here’s what we learned about what’s happening, and what you can do right now to minimize the issue.
What’s causing the marks?
The marks result from automated mail sorting machinery and come from two related sources. We’re told the “belt burn” effect occurs because pusher “fingers” on the DBCS (Delivery Barcode Sorter) have been temporarily deactivated by the USPS due to safety concerns. Without the pushers to guide pieces cleanly through, mailpieces sit against the belts in the stacker pocket longer than intended. Certain printed pieces — particularly those with specific paper stocks or finishes — are more susceptible to scuffing as a result.
What is the DBCS?
The Delivery Barcode Sorter (DBCS) is the high-speed automated machine used to sort letter-sized mail and postcards. It processes pieces at high speed, and belt contact during sorting is a normal part of the process — but the deactivated pusher fingers mean pieces aren’t being guided away from the belts as intended.
Is there a fix in the works?
Yes — we were told that the issue is well understood and is being treated as a priority. USPS Engineering is actively evaluating several proposed solutions and is close to selecting one. That said, once a solution is chosen, implementation is likely to take time given their current economic conditions. There is no confirmed timeline at this point. What can you do right now?
While the long-term fix is underway, USPS Engineering has identified a practical workaround: applying a coating to mailpieces significantly reduces the risk of scuffing. Here are their recommendations:
Recommended paper stock
9pt Williamsburg with a UV coating in a matte finish — or a paper with similar properties. The matte finish is important; high-static coatings can cause problems when pieces are picked off in the DBCS.
Why the finish matters
Coatings with high static cause pieces to stick together or behave unpredictably during machine pick-off. A low-static matte UV coating allows the machine to handle pieces more cleanly, reducing contact time with the belts.
For Click2Mail customers, this translates to selecting Full Color as your print color and “White Matte with Gloss UV Finish” as your Paper.
You can also explore mailing Notecards, which are similarly sized and protected by an envelope.
Summary
Scuff and belt burn on mailpieces is a known issue tied to temporarily deactivated pusher fingers on DBCS machines. Engineering is working toward a permanent solution, but in the meantime, opting for matte UV coating is your best defense. We’ll share updates as the fix progresses.
