[Federal Register Volume 59, Number 159 (Thursday, August 18, 1994)]
[Unknown Section]
[Page 0]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 94-20309]
[[Page Unknown]]
[Federal Register: August 18, 1994]
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POSTAL SERVICE
39 CFR Part 111
Revisions to Standards for Palletization
AGENCY: Postal Service.
ACTION: Proposed rule.
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SUMMARY: The Postal Service is proposing revisions to the Domestic Mail
Manual (DMM) standards concerning the preparation of mail on pallets.
The proposed revisions are intended to establish consistent preparation
standards for all classes of mail that result in the lowest combined
costs of handling palletized mail for the Postal Service and its
customers as well as to facilitate consistent service for palletized
mailings. To ensure that the Postal Service realizes the efficiencies
related to placement of mail on pallets, postal facilities will accept
pallets prepared only according to DMM pallet standards.
DATES: Comments must be received on or before September 19, 1994.
ADDRESSES: Address all comments to the Manager, Business Mail
Acceptance, U.S. Postal Service Headquarters, 475 L'Enfant Plaza SW,
Room 8430, Washington, DC 20260-6808.
FOR FURTHER INFORMATION CONTACT: Cheryl Beller, (202) 268-5166.
SUPPLEMENTARY INFORMATION: The proposed makeup standards are based on
three distinct overriding factors: (1) Joint industry/postal pallet
testing and modeling efforts; (2) current bulk mail center (BMC)
processing needs; and (3) roll-out of the Integrated Mail Handling
System (IMHS).
Industry/Postal Pallet Testing and Modeling
In August 1993, Postal Service and industry representatives met to
identify the barriers to increased palletization and to formulate a
process for assisting the Postal Service in its decisions on future
palletization efforts. It was determined that a two-pronged approach
should be undertaken (1) to explore the physical pallet-handling
processes for determining optimal requirements that serve both mailer
and Postal Service needs; and (2) to identify enhanced sortation
requirements for ensuring consistent levels of service for palletized
mailings.
To determine physical makeup requirements, a multifaceted pallet
test was commissioned. The first phase was conducted at the Chicago
BMC, beginning in February 1994; the second phase began in April,
adding three BMCs to the test. With the assistance of several mailers
who palletize, the Postal Service analyzed the effect of double- and
triple-stacking, shrinkwrapping, top capping, minimum and maximum
weights and heights, and short- and long-haul shipment effects.
Although there is still additional testing to do on some issues, what
has been learned is being incorporated into these new pallet standards.
Proposed standards are summarized below.
To determine the optimal sortation requirements, information on
postal workload factors was modeled by the Postal Service and members
of the Mailers' Technical Advisory Committee (MTAC). Although the
results of the modeling efforts have not aligned exactly, the consensus
of the industry and the Postal Service is that there are positive
opportunities to expedite processing available from selective increases
in palletization that can be achieved by providing options for lower
pallet minimum weights/volumes for certain categories of 5- and 3-digit
pallets. The Postal Service also believes that the proposed requirement
to prepare State distribution center (SDC) pallets for packages, trays,
and sacks will enhance processing opportunities.
BMC Processing Needs
In order to address existing capacity constraints and keep the BMC
network flowing smoothly, the Postal Service will need to move as much
mail as possible into cross-dock operations to move it farther into the
distribution network. The Postal Service's priority at this time is to
provide relief to the BMCs for the processing of letter mail in trays
and packages of flats. The Postal Service has relaxed standards on
pallet size for these mail types because it is anticipated that
palletization will provide the most relief to the BMCs, while not
extending Postal Service pallet-handling resources beyond supportable
limits.
As an added inducement to the finest depth of sort for pallets, as
well as relief for BMC operations heavily affected by unbanded trays,
the Postal Service proposes to require that all trays on destination
and mixed-BMC pallets must be banded, no matter where the pallets are
deposited, whereas trays on pallets made up to finer levels of
sortation, such as 5-digit and sectional center facility (SCF)
destinations, will no longer need to be banded.
Integrated Mail Handling System (IMHS)
The roll-out of the IMHS has begun, including funding for pallet-
handling equipment and the mail transport equipment needed to support
expanded palletization. Implementation of IMHS is expected in 1996.
Based on current equipment and planned IMHS deployments through
December 1994, the Postal Service is confident that it can support
increased pallet demand and processing needs, primarily for trays and
flats packages, that are likely to result if the proposed revised
standards are implemented.
Summary of Proposed Changes
Height Restrictions and Stacking Pallets
Pallet maximum height restrictions are being relaxed to 77 inches
for any single pallet, as well as for double- or triple-stacked
pallets, where stacking is allowed. The testing described above
indicated that pallet loads exceeding 77 inches are a problem because
of dock door and ceiling heights within postal facilities, and door and
internal heights of Postal Service trailers and other vehicles. This
maximum is consistent with the general acceptance throughout the Postal
Service of Postal-PAKs (cardboard sleeves used by the Postal Service to
contain mail) on pallets with a combined height of 75 inches, plus a 2-
inch allowance for packing material.
The 77-inch maximum will allow a greater amount of customer
participation because mailers will be able to double-stack and in some
cases triple-stack pallets while still allowing safe and efficient
pallet loading and unloading by Postal forklift equipment.
The Postal Service is proposing to allow mailers to triple stack
pallets holding bricklayed parcels and trays of letter-size mail, up to
the maximum allowable height and weight. Based on test results to date,
the Postal Service feels comfortable that it can safely and efficiently
handle such pallets. Tests with mailers are continuing to evaluate the
potential for safe and efficient handling of triple-stacked pallets of
packages.
If stacking pallets, mailers will be required to place pallets for
the same processing facility together to facilitate moving as much mail
as possible directly into cross-dock operations at BMCs for further
movement into the distribution network. For example, if a mailing
includes multiple pallets for two or more SCF service areas, the mailer
must stack and strap together pallets for the same SCF service area
instead of stacking together pallets for two different SCF service
areas. To obtain greatest use of transportation, mailers may stack and
band together pallets for different plants that remain after pallets
for the same processing plants have been banded together.
Pallet Boxes
The Postal Service proposes that mailers use only the following
types of pallet boxes, compatible with the IMHS, placed on pallets to
hold sacks of mail or parcels:
a. Full-size pallet boxes: 48 inches long, 40 inches wide, and more
than 60 inches high with triple corrugated fiberboard C and/or B flute
wall material, as certified by the manufacturer. When these boxes are
placed on a pallet, their overall height must not exceed 77 inches.
b. Half-size pallet boxes that meet the same construction standards
as full-size boxes and have the following dimensions: 48 inches long,
40 inches wide, and 34 inches high. When these boxes are placed on a
pallet, the overall height must not exceed 40 inches.
Top Capping
Top-capping requirements have been strengthened to ensure load
integrity because in the enhanced pallet environment both mailers and
postal operations will be transporting and handling an increased volume
of double- and triple-stacked pallets. In order to maintain the
integrity of the load, protect the customers' products, and provide a
flat surface for safe and efficient stacking, top caps (along with
shrinkwrapping and banding) are required on all pallets that either
customers or postal operations may have an opportunity to stack. Half-
size cardboard pallet boxes, which tend to collapse if another pallet
is placed on top, will not require top caps and will be permitted only
on the top pallet if double-stacked. Full-size cardboard pallet boxes
must never be stacked and will also not require top caps.
Top caps must be approximately 48 inches long, 40 inches wide, and
meet any of the following construction standards:
a. Five-wood boards with uniform edges and nine-leg pallet contact
for stacking;
b. Gaylord box end style, with minimum 3-inch side, with wall
material a minimum of double wall corrugated fiberboard C and/or B
flute;
c. Fiberboard honeycomb covered on both sides with heavy
linerboard, minimum \1/2\ inch thick; or
d. Corrugated fiberboard C flute sheet covering the entire top of
the load, with standard pallet solid fiberboard corner edge protectors.
Pallet Strapping
Proper strapping is needed to secure the top cap and load to the
pallet and to maintain the integrity of the load during shipping and
handling. Although at least two straps are required, the preferred
number of straps on a pallet is four, two placed in each direction. The
preferred strapping material is 5/8 inch wide plastic strapping with a
minimum breaking strength of 800 pounds. Steel strapping may be used if
it has a minimum width of 1/2 inch and has a greater minimum breaking
strength of 1,200 pounds required to ensure that it does not break and
cause injuries to postal employees handling pallets.
Prohibition of Courtesy Pallets
``Courtesy'' pallets (pallets that do not meet Domestic Mail Manual
(DMM) standards) are not allowed. Mailers must be authorized to
palletize under applicable standards, and all mail on pallets presented
to the Postal Service must be prepared in accordance with the standards
applicable to the class and type of mail placed on the pallets. The
relaxation in pallet minimum weights should promote and facilitate
customers' adherence to makeup requirements. These requirements allow
the Postal Service to move palletized mail as far down through the
postal mailstream as possible, reduce handlings, and improve service.
Exceptions for acceptance of pallets that do not meet DMM standards
would undermine these efforts and will not be permitted.
Tray Strapping
When strapping trays, mailers must use a single wrap of plastic
strap placed around the length of the tray that will ensure that the
tray maintains its integrity throughout processing and transportation.
The strap must not crush the tray or sleeve. Mailers should follow
these guidelines for strapping trays:
a. The strap should have a 10-pound minimum tension.
b. The preferred material for tray strapping (banding) is white or
yellow textured, extruded, commercial heat sealable polypropylene
strapping with a minimum 1-inch width and .025-inch thickness. If other
plastic banding material is used, it should have a minimum tensile
breaking strength of 80 pounds. The seal of the band should have a
minimum breaking strength of 60 pounds. The elongation of the alternate
material before yield should be less than 20 percent.
c. To minimize the cutting effect, the material should form a flat
bend with a minimum \1/4\-inch width when installed on the tray.
d. The seal should be accomplished by melting the ends of the strap
together using the heat or friction method or a knot or nonreusable
clasp. When forcibly opened, the seal should be incapable of being
resealed as initially installed and evidence of any attempt to reseal a
broken seal should be readily detectable. Knotted seals should not be
able to be retied.
e. The strap and seal should not be harmfully affected by moisture
or ambient temperature ranging from 40 to 125 degrees Fahrenheit.
f. Mailers should use strapping material manufactured and used
according to the best commercial practice for the type of banding.
As noted under the section titled BMC Processing Needs, the Postal
Service is proposing that mailers must strap all trays placed on
destination BMC and mixed-BMC pallets.
Pallet Sortation
As noted above, mailers will be required to prepare SDC pallets for
packages, trays, and sacks placed on pallets. In addition, mailers who
want an alternative to bedloading trays will be required to place them
on pallets in accordance with DMM standards. These standards were
initially published as guidelines in the Postal Bulletin (March 18,
1993; January 20, 1994). These changes will enhance processing
opportunities.
Although exempt from the notice and comment requirements of the
Administrative Procedure Act (5 U.S.C. 553(b), (c)) regarding proposed
rulemaking by 39 U.S.C. 410(a), the Postal Service invites comments on
the following proposed revisions of the DMM, incorporated by reference
in the Code of Federal Regulations. See 39 CFR Part 111.
List of Subjects in 39 CFR Part 111
Postal Service.
PART 111--[AMENDED]
1. The authority citation for 39 CFR part 111 continues to read as
follows:
Authority: 5 U.S.C. 552(a); 39 U.S.C. 101, 401, 403, 404, 3001-
3011, 3201-3219, 3403-3406, 3621, 3626, 5001.
2. Revise the following units of the Domestic Mail Manual as noted
below:
M030 CONTAINER PREPARATION
* * * * *
M033 Sacks and Trays
* * * * *
2.0 Basic Standards for Trays--Nonautomation Rates
* * * * *
2.4 Sleeving
Each tray must be sleeved, except that when all pieces in a mailing
originate and destinate in the delivery area of the same SCF, the
processing and distribution manager may (on request) issue a written
authorization to the mailer to submit the mailing in trays without
sleeves.
2.5 Strapping
Trays that are not placed on pallets (under M042 or M043) and that
are transported from the mailer's plant to a BMC, ASF, or AMF on USPS
or mailer transportation must also be secured by a plastic strap placed
tightly around the length of the tray. The strap must not crush the
tray or sleeve. When trays are placed on pallets under M042 or M043,
trays placed on BMC and mixed-BMC pallets must be secured by a plastic
strap, regardless of where the mail is deposited. Strapping is not
required on trays placed on pallets prepared to finer levels of
sortation.
3.0 Basic Standards for Trays--Automation Rates
* * * * *
3.6 Sleeving
Each tray must be sleeved, except that when all pieces in a mailing
originate and destinate in the delivery area of the same SCF, the
processing and distribution manager may (on request) issue a written
authorization to the mailer to submit the mailing in trays without
sleeves. The mailer must be able to produce this letter upon request of
the post office verifying mailings.
3.7 Strapping
Trays that are not placed on pallets (under M042 or M043) and that
are transported from the mailer's plant to a BMC, ASF, or AMF on USPS
or mailer transportation must also be secured by a plastic strap placed
tightly around the length of the tray. The strap must not crush the
tray or sleeve. When trays are placed on pallets under M042 or M043,
trays placed on BMC and mixed-BMC pallets must be secured by a plastic
strap, regardless of where the mail is deposited. Strapping is not
required on trays placed on pallets prepared to finer levels of
sortation.
M040 Palletization
M041 Pallets
1.0 Physical Characteristics
1.1 Construction
[In the second sentence, change ``65 cubic feet'' to ``80 cubic
feet.'']
* * * * *
1.5 Prohibition of Pallets Not Prepared According to Standard
All mail on pallets presented to the Postal Service must be
prepared in accordance with the standards applicable to the class and
type of mail placed on the pallets.
2.0 Top Caps
2.1 When Required
Top caps are required on all loaded pallets, regardless of weight,
holding letter trays (MM and EMM) of mail, packages of mail, sacks of
mail, and bricklayed parcels.
2.2 When Not Required
Top caps are not required on loaded pallets, regardless of weight,
holding sacks or parcels contained in full-size or half-size fiberboard
pallet boxes (``mailer paks'') prepared under 4.0.
2.3 Design
Top caps must be approximately 48 inches long, 40 inches wide, and
meet any of these construction standards:
a. Five-wood boards with uniform edges and nine-leg pallet contact
for stacking.
b. Fiberboard box end style, with minimum 3-inch side, with wall
material a minimum of double wall corrugated fiberboard C and/or B
flute.
c. Fiberboard honeycomb covered on both sides with heavy
linerboard, minimum 1/2 inch thick.
d. Corrugated fiberboard C flute sheet covering the entire top of
the load with standard pallet solid fiberboard corner edge protectors.
2.4 Securing
A top cap must be secured to the pallet, horizontal to the plane of
the pallet, with strapping or banding strong enough to keep the cap in
place so that it protects the mail and maintains the integrity of the
pallet load. At least two straps are required (one in each direction).
Strapping material may be plastic (at least 5/8 inch wide with a
minimum breaking strength of 800 pounds) or steel (at least \1/2\ inch
wide with a minimum breaking strength of 1,200 pounds).
3.0 Stacking Pallets
3.1 Double Stacking
Pallets may be double-stacked if the combined gross weight of the
stacked pallets is not more than 2,200 pounds; the heavier pallet is on
the bottom; the pallets are banded together with appropriate strapping
material to maintain their integrity during transportation and
handling; and the combined height of the stacked pallets does not
exceed 77 inches. Pallets with half-size fiberboard pallet boxes
holding sacks of mail or parcels must be the top pallet when pallets
are double-stacked.
3.2 Triple Stacking
Pallets holding MM or EMM trays of letter-size mail or bricklayed
parcels may be triple-stacked if the combined gross weight of the
stacked pallets is not more than 2,200 pounds. No other type of pallet
may be triple-stacked. The heaviest pallet must be on the bottom and
the lightest on the top; the pallets must be banded together with
appropriate strapping material to maintain their integrity during
transportation and handling; and the combined height of the stacked
pallets must not exceed 77 inches.
3.3 Pallets for Same Facility
Stack pallets for the same processing facility together. Mailers
may stack together pallets for different facilities that remain after
pallets for the same facilities are stacked and banded together.
[Renumber current 4.0 as 5.0; add new 4.0 as follows:]
4.0 Pallet Boxes
4.1 Definition
Mailers may use pallet boxes, constructed of triple wall corrugated
fiberboard C and/or B flute material (described below), placed on
pallets to hold sacks or parcels prepared under (M042, M043, or M044).
Sizes are as follows:
a. A full-size pallet box must be 48 inches long, 40 inches wide,
and more than 60 inches high. When placed on a pallet, the overall
height must not exceed 77 inches. Full-size pallet boxes may be
prepared only to BMC destinations.
b. A half-size pallet box must be 48 inches long, 40 inches wide,
and 34 inches high. When placed on a pallet, the overall height
(including a top cap if used) must not exceed 40 inches.
4.2 Securing
A pallet box must be secured to the pallet base with strapping or
banding strong enough to keep the box in place so that it protects the
mail and maintains the integrity of the pallet load. At least two
straps are required (one in each direction). Strapping material may be
plastic (at least 5/8 inch wide with a minimum breaking strength of 800
pounds) or steel (at least 1/2 inch wide with a minimum breaking
strength of 1,200 pounds).
[Revise renumbered 5.0 as follows:]
5.0 Preparation
* * * * *
5.2 Minimum Load
In a single mailing, the minimum mail loads per pallet are as
follows:
a. 250 pounds for packages of second- or third-class mail placed on
5-digit and 3-digit pallets (optional); 500 pounds for other sacks,
packages, bundles, and parcels on pallets, except that up to 10% of the
pallets (not including 5- and 3-digit pallets that contain less than
500 pounds) in any mailing or plant-verified drop shipment job may
contain less than 500 pounds, but not less than 250 pounds, of mail.
This 10% exception may be applied to all mailings that are part of the
same mailing job.
b. Two layers of EMM trays.
c. Three layers of MM trays.
[Renumber 5.3 as 5.5; add new 5.3 and 5.4 as follows:]
5.3 Maximum Load Weight
The maximum load weight is 2,200 pounds (mail and pallet) for all
pallets.
5.4 Maximum Load Height
The combined height of a pallet and its load must not exceed:
a. 77 inches for sacks, packages, bundles, parcels, and full-size
fiberboard pallet boxes.
b. 40 inches for half-size fiberboard pallet boxes.
c. Five layers of EMM trays.
d. Six layers of MM trays.
M042 Second-Class Mail
* * * * *
4.0 Preparing Pallets of Packages or Bundles
[Delete current 4.1 and renumber 4.2 through 4.5 as 4.1 through 4.4,
respectively; revise renumbered 4.2 as follows:]
* * * * *
4.2 Presort and Labeling
* * * * *
e. SDC (required); use L201 for Line 1.
* * * * *
5.0 Preparing Pallets of Copalletized Flat-Size Publications
[Delete current 5.3 and renumber 5.4 through 5.10 as 5.3 through 5.9,
respectively; revise renumbered 5.3 as follows:]
* * * * *
5.3 Presort and Labeling
* * * * *
e. SDC (required); use L201 for Line 1.
* * * * *
6.0 Preparing Pallets of Sacks
[Delete current 6.1 and renumber 6.2 through 6.4 as 6.1 through 6.3,
respectively; revise renumbered 6.2 as follows:]
* * * * *
6.2 Presort and Labeling
* * * * *
e. SDC (required); use L201 for Line 1.
f. Transfer hub (optional).
* * * * *
7.0 Preparing Pallets of Trays (Letter Mail)
7.1 Tray Preparation
Trays must be prepared in accordance with the standards applicable
to the class of mail and rate claimed.
7.2 Pallet Presort and Labeling
Pallet presort sequence and labeling:
a. SCF (required); use L002 (facilities in Column A identified with
three bullets or facilities in Column B, as applicable) for Line 1.
b. SDC (required); use L201 for Line 1.
c. BMC (required); use L705 for Line 1.
d. Mixed-BMC (required); label to origin BMC; use L705 for Line 1
and show any required processing code right-justified on Line 2.
7.3 Separation of Mailings
Trays from automation rate mailings must not be placed on pallets
with trays from nonautomation rate mailings.
M043 Third-Class Mail
* * * * *
4.0 Preparing Pallets of Packages or Bundles
[Delete current 4.1 and renumber 4.2 through 4.6 as 4.1 through 4.5,
respectively; revise renumbered 4.2 as follows:]
* * * * *
4.2 Presort and Labeling
* * * * *
e. SDC (required); use L201 for Line 1 (deposit pallet at BMC
serving 3-digit ZIP Code on Line 1 if DBMC rate is claimed).
f. BMC (required); use L705 (or L708 if DBMC rate is claimed) for
Line 1.
g. Mixed-BMC (required); label to origin BMC, use L705 for Line 1
and show any required processing code right-justified on Line 2.
* * * * *
4.5 Sacks
[Change the reference in the first sentence from ``4.3'' to ``4.2.'']
* * * * *
6.0 Preparing Pallets of Copalletized Flat-Size Mailings
6.1 Standards
[Change the references from ``4.2 through 4.6'' to ``4.1 through
4.5.'']
* * * * *
6.4 Size
[Delete current 6.4 and renumber 6.5 through 6.12 as 6.4 through 6.11,
respectively.]
* * * * *
6.10 Sacking
[Change the reference in the first sentence from ``4.3'' to ``4.2.'']
* * * * *
7.0 Palletizing Machinable Third-Class Parcels
[Delete current 7.1 and renumber 7.2 through 7.5 as 7.1 through 7.4,
respectively.]
* * * * *
7.2 Line 2
[Change the reference at the end from ``7.2'' to ``7.1.'']
7.3 \3/5\ Presort Rate
[Change all references from ``7.2'' to ``7.1.'']
* * * * *
8.0 Palletizing Third- And Fourth-Class Machinable Parcels
8.1 Standards
[Change the reference from ``4.2 through 4.6'' to ``4.1 through 4.5.'']
8.2 Size
[Delete current 8.2 and renumber 8.3 through 8.8 as 8.2 through 8.7,
respectively.]
8.3 Line 2
[Change the reference at the end from ``8.3'' to ``8.2.'']
8.4 \3/5\ Presort Rate
[Change all references from ``8.3'' to ``8.2.'']
* * * * *
9.0 Preparing Pallets of Sacks
[Delete current 9.1 and renumber 9.2 through 9.4 as 9.1 through 9.3,
respectively.]
* * * * *
9.2 Line 2
[Change reference at end from ``9.2'' to ``9.1.'']
* * * * *
10.0 Preparing Pallets of Trays (Letter Mail)
10.1 Tray Preparation
Trays must be prepared in accordance with the standards applicable
to the class of mail and rate claimed.
10.2 Pallet Presort and Labeling
Pallet presort sequence and labeling:
a. SCF (required); use L002 (facilities in Column A identified with
three bullets or facilities in Column B, as applicable) for Line 1.
b. SDC (required); use L201 for Line 1 (deposit pallet at BMC
serving 3-digit ZIP Code on Line 1 if DBMC rate is claimed).
c. BMC (required); use L705 for Line 1.
d. Mixed-BMC (required); label to origin BMC; use L705 for Line 1
and show any required processing code right-justified on Line 2.
10.3 Separation of Mailings
Trays from automation rate mailings must not be placed on pallets
with trays from nonautomation rate mailings.
M044 Fourth-Class Mail
* * * * *
3.0 Preparing Pallets of Packages
[Delete current 3.1 and renumber 3.2 through 3.5 as 3.1 through 3.4,
respectively.]
* * * * *
4.0 Preparing Pallets of Machinable Parcels
[Delete current 4.1 and renumber 4.2 through 4.6 as 4.1 through 4.5,
respectively.]
* * * * *
4.2 Line 2
[Change the reference at the end from ``4.2'' to ``4.1.'']
* * * * *
5.0 Preparing Pallets of Special Fourth-Class Presort
[Delete current 5.1 and renumber 5.2 and 5.3 as 5.1 and 5.2,
respectively.]
* * * * *
5.2 Line 2
[Change the reference at the end from ``5.2'' to ``5.1.'']
* * * * *
M048 Automation-Compatible Flats
* * * * *
2.0 Package and Pallet Preparation
* * * * *
2.2 Pallets
Pallets must be prepared under the general standards in M041.
* * * * *
An appropriate amendment to 39 CFR 111.3 to reflect these changes
will be published if the proposal is adopted.
Stanley F. Mires,
Chief Counsel, Legislative.
[FR Doc. 94-20309 Filed 8-17-94; 8:45 am]
BILLING CODE 7710-12-P
