21st Century Mail4-State Code
Implications for Flats Mailers
& the IDEAlliance Process
Jonathan PhillipsChair, IDEAlliance Intelligent
Mail Barcode Task ForceJuly 24, 2007
4-STATE CODE
Postnet and Planet
– 22 bars/inch
– 62 and 72 bars in the code
– Full bar 0.115in to 0.135in
4 State Code
– 22 bars/inch
– 65 bars in the code
– Full bar 0.134in to 0.230in
4-STATE CODE
Postnet and Planet
– Simple algorithm, direct correlation
– Readily visually read
4 State Code
– Complex encryption algorithm
– Cannot be read without scanner
What’s the fuss about ?
Primarily:
Size
4-STATE CODE
Industry Position
Many printers use 8-line 0.167in-pitch raster inkjets
Many printers use 1in binary array inkjets.
In both cases, code heights above 0.125in mean less lines of text are available.
Politics of position A synopsis of the situation that presented itself is very simple.
As the USPS move from POSTNET to the 4sc it is imperative that existing technologies deployed and controlled within the printing industry, representing an estimated total replacement cost of 250,000,000 dollars can print the new code satisfactorily, and that the USPS does not burden industry with these costs. The proposed international standard for 4sc the USPS were planning to adopt would have necessitated machine replacement.
As a result of this state of affairs and in acknowledgement of the IDEAlliance communications on the issue. work was carried out over a number of years by the USPS, with ongoing assurances from the USPS that all printer technology would be accommodated.
This was planned to be accomplished through a change to the height and other related dimensional specification of the Barcode.
In Feb 07 the USPS shocked the publication printing market when they announced that the 4sc would remain at the international specification height and specifically citing failure of UFSM machines in testing the modified specification as the cause.
The USPS Feb 2007 communication extract
Most Testing started Summer 2006
Testing on AFSM 100 & APPS
– Testing showed no degradation @ .125” height
Testing done on UFSM
– Significant read rate decline at .125” height
• 95+% at .134” height
• ~25% at .125” height
As a result, flat specification can not be adjusted below .134” at this time
Establish a specification that allows the use of existing predominant technologies to print the 4-state barcode without compromising, yield, productivity, or flexibility.
1.Determine the optimal inkjet 4-state barcode specification through field evaluation of the UFSM with current inkjet technology
2.Pressure the USPS to change the 4-state barcode specification to allow printing with current inkjet technology
IDEAlliance technical team 4SC
4-STATE CODE
IDEAlliance Practical Evaluation
Specific barcode items for consideration
Height
Non-linearity
Address block
Height - Overall
Raster printer bar height impacted by
non-printer variables:
– Book thickness (+/-1/8in for selective)
– Book curvature (esp. stitched)
printer variables:
– Head height
– Operator settings
Height – Overall
Where is the bar measured in practice?
Effective bar height
measure point
Height - Voids
Information from USPS-B-3200 and Pub. 25
0.0050.005
Current specification is 0.005in
Height - Voids
Constructive use of voids
– Permit taller bar with less drops (greater speed or less skew)
– Reduce implications of drop-diameter on code quality
Drop0.0150
Void0.006
Void0.004
Drop0.0165
Diagram showing void and drop diameter comparing MEK and Acetone fluids with same 0.180in bar height.
Height - Voids
Example
– 9dp at full spec height 0.230in
– Shows voids ~0.012in
Height
Action
Determine height sensitivity
Determine impact of voids
Information from USPS-B-3200 and Pub. 25
Non-linearity (skew)
Linear skew
Information from USPS-B-3200 and Pub. 25
< +5° max > -5° max
CL
CL
Baseline skew
< +5° max > -5° max
CLCL
Bar skew
Non-linearity (curve)
Curve
– Formation of the raster means each drop travels a different distance
Diagram from UPU S18d-5
Non-linearity (hook)
Hook
– First drop slows more than subsequent ones due to aerodynamic effects
Non-linearity
Action
With samples of each skew type:
– Determine the perceived center line of the bar (bar-pitch)
– Determine the effective bar width
– Determine the effective inter-bar gap
– Considerations for skew angle
Address block line-gap
Information from USPS-B-3200 and Pub. 25
PlaceStampHere
4.125
9.500
JOHN DOE 91 MAIN STREET ANYTOWN MD 01234-5678
UNITED STATES POSTAL SERVICE5501 ANYWHERE HWY MERRIFIELD VA 22082-8412
01 234 567094 987654321 01234 5678 91
.040 MIN.500 MAX
Align to the leftmostposition of the barcode
PlaceStampHere
4.125
9.500
PlaceStampHere
4.125
9.500
JOHN DOE 91 MAIN STREET ANYTOWN MD 01234-5678
UNITED STATES POSTAL SERVICE5501 ANYWHERE HWY MERRIFIELD VA 22082-8412
01 234 567094 987654321 01234 5678 91
.040 MIN.500 MAX
Align to the leftmost
JOHN DOE 91 MAIN STREET ANYTOWN MD 01234-5678
UNITED STATES POSTAL SERVICE5501 ANYWHERE HWY MERRIFIELD VA 22082-8412
01 234 567094 987654321 01234 5678 91
.040 MIN.500 MAX
Align to the leftmostposition of the barcodeposition of the barcode
Address Block Gap
Action
Test to determine if gap can be reduced from the current 0.040in to the inter-text gap of 0.028in
Information from USPS-B-3200 and Pub. 25
IDEAlliance Practical Evaluation with USPS
Testing has started at Carol Stream, IL USPS facility
UFSM1000 evaluation focus
Results show the UFSM will not read codes under .134”
However AFSM reads very well indeed
Merlin being modified
Establish a specification that allows the use of existing predominant technologies to print the 4-state barcode without compromising, yield, productivity, or flexibility.
1.Determine the optimal inkjet 4-state barcode specification through field evaluation of the UFSM with current inkjet technology
2.Pressure the USPS to change the 4-state barcode specification to allow printing with current inkjet technology
IDEAlliance technical team 4SC
4-STATE CODE
USPS MTAC announced:
1. Reduced height minimum from 0.134in to 0.125in
2. Increased address block gap from 0.028in to 0.040in
3. Increased voids to .010”
Formal change expected by Feb 2008
Other Industry/USPS testing activities continue
IDEAlliance technical team 4SC
4-STATE CODE
USPS Schedule – May 1, 2007
Intelligent Mail Barcode acceptable for automation discounts
OneCode Confirm for First-Class, Periodicals and Standard
OneCode ACS for First-Class, Periodicals (Standard – Fall ’07)
Intelligent Mail Barcode for Flats
USPS Schedule – 2007
Barcode acceptable for automation discounts at original heights.
Letter of dispensation required for lower heights
Codes below .134 will fail Merlin and UFSM
Intelligent Mail Barcode for Flats
USPS officially embeds new specifications into DMM “Intelligent Mail®” around Feb 08
FSS roll-out: From Oct 2008
IMB Flats Mandate: 2009
Postnet invalid 2009
CASS-DPV Mandate: July 2009
Intelligent Mail Timeline Future Events
JetArray – Anatomy Detail
Domino Amjet Incorporated
William Tell
1290 Lakeside Drive
Framingham
Gurnee
New York landing
IL, 60031
Each black line represents top most drop of JetArray Print
The 1st line on a JetArray can deflect further asThere is no line below to impede belowThus this line can be up to about .166” high.Taller bars will have print defects
.166667”
.166667”
.166667”
.166667”
.166667”
.166667”
.166667”.040” gap required here will reduce to .028”
Each arrow represents deflection direction
JetArray Use in IMB?
Minimum was .115” Add .010” to get .125”
Practical Maximum was .126”Due to equipment andAdjacent line limits
Practical Maximum becomes .138”worst case (printing into text)and more like .152” + when printingaway from text (Printing on line 1)
Summary 4 State and JetArray
Can the JetArray print 4sc = Yes
Best printed from Line 1 = Educate the customer
Conversion Packages may be required
Letter of Dispensation will be required for JetArray up until 2008 because .134” is not practical with a .040 gap in an 8 line address
CASS certified mail preparation software with 4sc algorithm will be needed
Selective book thickness of up to 3/16th inch can be accommodated with CAREFUL setup
Summary IDEAlliance tasks
1) 4sc manual “Intelligent Mail”
What you need to know
2) Managing the USPS for this need
Published dispensation process
Managing disputes (automation failures at remote sortation facilities)
Managing the 20 bar 24 bar limit on Scitex 5120 products
Managing the proposed new technical specification
3) Committee for the specification
Ensure the technical specification detail represents industry needs
4) Interim management
Letter of dispensation method
Read Rates (may be poor on UFSM despite letter Printers and Publishers need to manage relationship and communicate well prior to roll out of USPS equipment and modified specification)
Thank You!