Print & Mail

Mail Sorting

By 29 January 2026February 13th, 2026No Comments

How Does Mail Sorting Help Businesses Save on Postage?

Businesses try finding new methods to cut postage expenses and save money. They rely on dropshipping, mail sorting, commingling, and more techniques to get discounted postal rates.

The United States Postal Service (USPS) encourages senders to presort their mail pieces to reduce manual effort and handling time. It offers discounted prices to reward commercial shippers who go the extra mile and categorize their mailers!

But how is mail sorted?

What is the process, and who does it?

This blog covers this question in-depth. You will also learn about the history of sorting mailers and how companies go about this process.

What Does Mail Sorting Mean?

The process of sorting mail is a mechanism through which postal services determine the routes and destinations for delivering mail. While it was once a manual task, it has become a largely automated process, thanks to the assistance of specialized machines.

Businesses in all sectors have started using mail sorting systems. It lets them prepare their items before dispatch and qualify for postage discounts.

Taking advantage of presort discounts can slash the cost of First-Class Mail. Many companies have adopted mail sorters to streamline the handling of incoming mail, including checks, orders, and correspondence.

Manual mail sorting was the norm throughout the 20th century. Postal workers read and slotted mailers into designated compartments through the “pigeon-hole message box” system.

However, the 1920s witnessed the advent of early versions of mechanical mail sorters. The Dutch company Werkspoor produced the Transorma.

This mail sorting system commenced operation in Rotterdam in 1930 and reached other Dutch cities. Brazil, Belgium, Argentina, Venezuela, and Canada had adopted the Transorma by the mid-1950s.

The Transorma 5/300 had upper and lower sections. It also had a conveyor belt for transportation and five sorting keyboards. Operators entered the sorting code based on the mailing destination.

Subsequently, this sorting mail mechanism helped automatically guide letters to a designated tray. It would let these items deposit into one of 300 chutes.

The Transorma boasted an impressive sorting rate of 15,000 letters per hour.

How Is Mail Sorted?

Senders can initiate the process of sorting mail once they design, print, and address their mailpieces. It involves four crucial steps to ensure efficient and accurate sorting.

Here is a breakdown of what you need to do:

#1 Buy the Supplies

The first step in mail sorting is gathering the essential materials. Businesses can procure most of these supplies at the Business Mail Entry Unit (BMEU) within their local Post Office during business hours.

The BMEU clerks can assist senders in locating the precise items they require.

Please remember that most BMEUs offer a dedicated work area for customers where senders can find the necessary supplies. Feel free to ask for assistance if you need help locating a specific product.

The USPS offers a range of items free of charge to aid the mail sorting efforts. These include:

Trays

One can choose from 1-foot and 2-foot trays for standard letters. It is an excellent idea to take a few of each size and return any unused trays, primarily for first mailings. Thus, shippers can gain a better understanding of their future needs.

Additionally, special EMM trays can help sort “tall” letters.

These trays are deeper and available in 2-foot lengths. First-Class Mail flats require deep tubs or flat trays for mail sorting processes. However, USPS Marketing Mail flats go into white or clear sacks.

Bundle Labels.

Bundle labels are colored stickers firms use to identify their bundles. They can buy a roll of four available stickers: 5, 3, A, and X. 

Tray Lids or “Sleeves”

These lids, or “sleeves,” are essential for each tray. Also, shippers should ensure they match the tray size (1-foot or 2-foot).

Flat trays also require these sleeves for better security and transportation.

Container Labels

Each container, whether a tray or sack, must bear a label indicating the mail’s destination. The BMEU clerk can assist you in selecting the suitable labels.

Always use the USPS cardstock material instead of flimsy stickers or paper. It helps smoothen mail sorting and get the necessary benefits that senders desire.

Strapping Material

A single strap running along the length of the sleeved tray is necessary to secure the mail trays. You can find strapping material at most office supply stores.

Labeling Lists

These lists contain ZIP Codes with corresponding postal facility destination information. They help properly label bundles, trays, sacks, and pallets to the correct destinations.

Labelling lists are available for different mail types on the Postal Explorer website. Access these lists beforehand to learn “how is mail sorted” and prepare yourselves.

Postage Statement

Shippers use postage statements to record the number of pieces in a mailing and calculate the applicable postage. Hardcopy postage statements are available on the Postal Explorer website and at local BMEUs.

Quick Service Guides (QSGs)

These two-page guides provide clear instructions using text and visuals. They are helpful for sorting mail of any class or presort level. Senders can find them online and in hard copy format at the local BMEU.

Shippers are well-equipped to start sorting after obtaining the necessary supplies. The next step involves putting these acquired items to good use.

Editor’s Note: Businesses can skip through these time-consuming and expensive steps by using PostGrid’s direct mail API. It helps send offline mailers through mail automated solutions, managing everything from preparing items to distributing them online.

Also, PostGrid offers the lowest rates and presorts the mailers beforehand to fetch compelling postal discounts.

#2 Sorting Mail

The process of sorting mail plays a significant role in reducing postage and ensuring efficient deliveries. Understanding this technique benefits senders in many more ways. 

Presorting involves grouping mailers by ZIP codes. USPS postal workers organize all mail pieces going to the same place into bundles or trays. They begin the mail sorting process with specific areas and progress to more general destinations. 

Also, they combine the remaining items for efficient mail processing.

Some individuals choose not to presort items and instead pay the entire First-Class Mail price. They affix stamps to their mailpieces and deposit them in a collection box.

This method is straightforward. But alternative options exist for those who want to benefit from lower postage without the hassle of sorting mail themselves.

One can employ a presort bureau or letter shop to handle mail presorting and preparation. It can help those who prefer to refrain from engaging in manual mailer sorting.

They can take advantage of reduced postage rates without personal involvement in the mail sorting process.

#3 Prepare the Mail Containers

Presorting is crucial to ensure the efficient distribution of your correspondence. But how is mail sorted? It all begins with preparing the mailer containers. This process involves several essential steps to ensure the envelopes and small parcels reach their intended destinations on time.

  • Carefully sort the mail into the appropriate trays, each designated for a specific size and destination. Complete mail sorting processes accurately to prevent any mix-ups during the distribution process.
  • Then, sleeve and strap the trays after getting the items in the correct slots. Here is how senders can do it:
    • Confirm that each tray has the correct label, indicating its size and destination. This step ensures that you maintain accuracy throughout the process.
    • Place the appropriately sized sleeve, a paperboard “jacket,” over each letter tray. Each tray comes with a matching sleeve, ensuring a snug fit. The sleeves slip over the entire tray, leaving the ends exposed.
    • Secure each tray using a single strap that goes around the length of the sleeved tray. This step keeps your mail neatly organized and intact during handling and transportation.

Tips for Mail Sorting and Container Preparation:

  • Use strapping materials to secure the mailers throughout processing and transportation.
  • Some Post Offices may waive the strapping requirement for containers of local mailers. Inquire at your Business Mail Entry Unit for the details.
  • While senders must strap each tray, it is worth noting that the Post Office does not provide strapping material. They can find it in rolls at most supply stores.
  • The BMEU offers special lids with cinching mechanisms attached to the handle to let shippers manage flat trays (deep tubs). They ensure item security during the mail sorting processes and beyond.

#4 Complete the Postage Statement

You are ready to fill out the postage statement once you complete the steps and prepare the containers.

This statement is a vital part of the mail sorting and distribution process. It ensures the USPS accounts for every mail piece and processes the delivery smoothly!

The postage statement has blank space for shippers to mention their commercial mailing permit number and business name.

Here are some tips to fill out USPS postage statements:

  • Access Postage Statements: Please head to the Postal Explorer home page and click “Business Solutions” to find a mail sorting statement. Navigate to the “Postage Statements” section in the top toolbar. Here, access the read-only version of any postage statement.
  • Destination Entry Discounts: Take advantage of potential cost savings by sorting mail at specific postal facilities offering destination entry discounts. While many small-scale shippers drop items at their local Post Office, you could be eligible for these discounts if you maintain a permit at a Sectional Center Facility (SCF) postal facility. Inquire at the local facility to determine whether you qualify for these reduced rates.
  • Complete PS Form 3602-EZ and 3602-NZ: They help send USPS Marketing Mail flats, letters, and postcards.
  • Selecting the Appropriate Price: Consult the back of your postage statement, outlining many postage prices. These rates include a range of discounts for automating the mailers and sorting mail at different postal facilities.

Please note that senders must pay the rate the items qualify for, irrespective of the discounted price range. They might see lower prices listed on the statement. However, achieving those rates may require extra effort. Hence, explore the options and calculate the associated costs.

  • Keeping a Copy for Your Records: Make a statement before heading to the Post Office for storing records. It helps ensure you have the necessary documentation for mail sorting and postage.
  • USPS Marketing Mail Weight-Based Charges: Heavier USPS Marketing Mail pieces are subject to a per-piece and a per-pound charge. Seek assistance from the clerk at the BMEU for precise calculations.

Also Read: Direct Mail for Banks

How Do the Automated Sorting Machines Work (Transorma)

Presorting mailers has come a long way from its manual origins. The postal workers would earlier complete the daunting task of sorting mail by hand.

As discussed above, they used pigeon-hole message boxes similar to cubbies in university offices. The postal services divided the process into a hierarchical structure at larger sorting stations across the US.

Sorters would arrange mail based on delivery routes at smaller stations. Other facilities categorized the items by destination states or cities.

Mailers would travel through these sorting stations until they reached the local Post Office. Then, the employees would complete mail sorting based on delivery routes. This system had its limitations, relying on the sorter’s memory and physical reach.

It continued most of the 20th century until the invention of the first automated sorting machine, the Transorma.

The 1920s saw many mechanical sorting device tests. However, the Transorma, short for “TRANsport and SORting,” and the inventors (Marchland and Andriessen) marked a significant advancement.

The Transorma employed a sorter who read addresses and inputted routing codes via a keyboard. They would also print the addresses in colored ink on mail items.

Subsequently, another person responsible for mail sorting would manually route the mail. The machine used these codes to program switches and direct mail to the appropriate bin.

While Transorma models could feature varying bins, most had 250 or 300. Some single-user machines employed a different sorting mechanism.

Automated presorting started a new era, leaving behind the constraints of manual labour. It significantly enhanced efficiency in how mail is sorted and delivered.

Also Read: Real Estate Direct Mail Marketing

How Can PostGrid Assist Businesses in Sorting Mail?

PostGrid’s direct mail API lets businesses get efficient and cost-effective solutions for their mailing needs. We streamline the entire process, and senders can benefit from our capability to conduct presorting automatically.

It ensures senders can sort their mailers precisely and deliver them accurately. This feature alone can save businesses valuable time and resources they would otherwise spend manually presorting mail.

One of the primary advantages of PostGrid’s API is its low prices. Automating the mail sorting process allows organizations to reduce functional costs significantly.

It makes direct mail marketing campaigns more budget-friendly. Lower prices mean you can reach a broader audience without breaking the bank.

PostGrid’s automated direct mail services provide many other benefits beyond mail sorting and cost savings. It ensures the mailers arrive at the correct addresses, enhancing the success of your marketing efforts.

Additionally, it allows for customization and personalization of mail content. These elements result in more engaging and effective communication with the target audience.

Businesses can prepare and send their marketing, transactional, and compliance mailers with PostGrid. We provide many printing and mailing options, letting them remain flexible.

Also, we add Intelligent Mail Barcodes (IMBs) to every item. They allow senders to track their items and stay informed throughout USPS deliveries!

Also Read: 10 Real Estate Postcard Ideas For Success

Conclusion

Presorting mail pieces enables firms to save money and streamline deliveries. They help the USPS by categorizing mailers based on ZIP code. Hence, the Post Office offers them exciting discounts as a reward!

Businesses can conduct mail sorting in-house by following the steps in this blog. However, it takes time, resources, and effort.

Thus, choosing PostGrid to handle your print and mail needs with presorting is the best choice.

Sign up for more information on mail sorting and how we simplify the process!