Quoted from Daditude:If i wrote a letter and folded it over, it would have been thicker. I ship hundreds of items a year, so i am quite familiar with it. I have noticed this disturbing trend in post offices for awhile now. They have changed MANY rules to raise prices...in addition to outright increasing prices as well.
I realise this is an older post, but as someone that works on the DBCS machines that process the mail, maybe I can shed some light on the subject. This isn't a conspiracy to get you to move up to parcel size to make more money for the USPS. Honestly, the clerks probably don't care. Thickness, size of envelope, uniformity of envelope all play a part in rates and restrictions. If your key fobs are rigid, they will get stuck in a machine. If they are loose and not secured in the envelope, they will most likely tear through the envelope. The DBCS machines can process 25 to 40 thousand letters an hour when running properly and not down due to items caught in the rollers, belts, or gates.
Next time you send out some fobs, instead of sending them first class parcel, try securing them to a postcard in an envelope, and asking the clerk for first class letter, non machinable. It's an additional .21 cents, but still cheaper than first class parcel.