USPS Shrank 11 Popular Free Mailing Boxes and Envelopes

USPS shrank 11 of its free branded mailing envelopes and boxes last month which includes a number of popular sizes shippers frequently use.

The Postal Service updated its online Postal Store with the new sizes. But depending on inventory, especially of the less popular boxes and envelopes, shippers will continue to receive the previous sized items until supplies last.

In addition, local Post Office locations may still have some older inventory as well until their supplies are exhausted.

While USPS did not directly link these changes to its 10-year Delivering For America plan, it appears they are part of the overall plan to handle larger parcel volumes.

The Postal Service said the reason they changed the dimensions is to allow the boxes and envelopes to be processed on mail processing equipment more efficiently. This will increase visibility and reduce the need for manual package sortation, they claim.

USPS produces and fulfills over 181 million Standard and Specialized Expedited Packaging Supplies (Priority Mail Express, Priority Mail, and Global Express Guaranteed) orders annually.

The impact of the size changes on USPS branded free mailers seems minor at first glance.

However, one box (Priority Mail Regional Rate Box B) shrank significantly and the size adjustments affected several flat rate mailers. For some shippers, this may cause problems if they frequently ship items that were already tightly packed in the older box sizes.

In the table below, we divided the changes into service levels:

• GXG – Global Express Guaranteed
• Express – Priority Mail Express
• Military – Priority Mail APO/FPO
• Flat Rate – Priority Mail Flat Rate Box (Standard and Regional)

Service	Item	Item #	Old Dimension	New Dimension	Change
GXG	Global Express Guaranteed Tyvek Envelope	EP16B	15-1/8” (L) x 11-5/8” (W)	15” (L) x 11-5/8” (W)	Length is 1/8″ smaller
Express	Priority Mail Express Tyvek Envelope	EP13C	15-1/8” (L) x 11-5/8” (W)	15” (L) x 11-5/8” (W)	Length is 1/8″ smaller
Express	Priority Mail Express Box	1093	15-5/8” (L) x 12-1/2″ (W) x 3-1/8” (H)	15” (L) x 12″ (W) x 3-1/8” (H)	Width is 1/2″ smaller, Length is 5/8″ smaller
Military	Priority Mail APO/FPO Flat Rate Box – Large	MILIFRB	12-1/4” (L) x 12-1/4” (W) x 6” (H)	12-1/4” (L) x 12” (W) x 6” (H)	Width is 1/4″ smaller
Military	Priority Mail APO/FPO Tyvek Envelope – MILIPAC	MILIPAC	15-1/8” (L) x 11-5/8” (W)	15” (L) x 11-5/8” (W)	Length is 1/8″ smaller
Priority	Priority Mail Tyvek Envelope	EP14	15-1/8” (L) x 11-5/8” (W)	15” (L) x 11-5/8” (W)	Length is 1/8″ smaller
Priority	Priority Mail Box	1092	13-11/16” (L) x 12-1/4” (W) x 2-7/8” (H)	13-11/16” (L) x 12” (W) x 2-7/8” (H)	Width is 1/4″ smaller
Priority	Priority Mail Box	1095	15-5/8” (L) x 12-1/2″ (W) x 3-1/8” (H)	15” (L) x 12″ (W) x 3-1/8” (H)	Width is 1/2″ smaller, Length is 5/8″ smaller
Priority	Priority Mail Box	Box 7	12-1/4” (L) x 12-1/4” (W) x 8-1/2” (H)	12-1/4” (L) x 12” (W) x 8-1/2” (H)	Width is 1/4″ smaller
Flat Rate	Priority Mail Flat Rate Box – Large	LFRB	12-1/4” (L) x 12-1/4” (W) x 6” (H)	12-1/4” (L) x 12” (W) x 6” (H)	Width is 1/4″ smaller
Flat Rate	Priority Mail Regional Rate Box B	RRB-B2	16-1/4” (L) x 14-1/2” (W) x 3” (H)	15” (L) x 12” (W) x 3” (H)	Width is 2-1/2″ smaller, Length is 1-1/4″ smaller

High Volume Mailers Box Size Changes

In addition to the above 11 adjustments to boxes and envelopes, USPS also shrunk three specialized boxes and envelopes reserved for high-volume shippers that spent over $75,000 in with the Post Office.

These include:

• Box #8, Specialized Priority Mail Box, width reduced by 2-1/4″ (new dim: 14-1/4” (L) x 12” (W) x 6-1/2” (H))
• Box # 17, Specialized Priority Mail Box, width reduced by 1/4″ and length reduced by 4-1/4″ (new dim: 15” (L) x 12” (W) x 4-1/2” (H))
• PM003, Specialized Priority Mail Bubble Envelope, length reduced by 1/8″ (new dim: 15” (L) x 11-5/8” (W))

These boxes are not available at Post Office or on the USPS online Postal Store and shippers must have prior approval from the Postal Service to gain access to them.

Do Not Throw Out Old USPS Boxes

The Postal Service will continue to accept and honor flat rate shipments with older boxes. Shippers do not need to throw out old inventory.

We do suggest shippers that stock their own inventory of the free USPS boxes and envelopes ensure they rotate through old stock first.

All listed dimensions are outside dimensions.

If you liked this article and would like to engage with other small business entrepreneurs selling on marketplaces, join our . You can also find us on , , , and or sign up for our newsletter below.