Patented Solution Reduces Cost of Large Scale Face Mask Mailing | Nonprofit

10/19/2020 RRD

Patented Solution Reduces Cost of Large Scale Face Mask Mailing | Nonprofit

Nonprofit organization leverages Flex Mailer™ to send packages at USPS automated flats’ rates 


One of the largest nonprofit, nonpartisan organizations in the United States wanted to show support to its volunteers during the pandemic by providing them with reusable face masks. With an order for mailing and distributing over 60,000 masks, they needed a partner with proven expertise in efficient fulfillment and postage options. 

The challenge included a need for lower postage costs and a mailing package that would stay uniform in thickness with no product shift during transit, which would potentially bump up the postage rate.  


RRD collaborated with the USPS to deliver postage savings while managing the kitting and distribution services for an efficient, comprehensive solution. 

RRD’s patented Flex Mailer was a good fit for the face mask mailing, with a postage guarantee from USPS equal to the average nonprofit rate for an automated flat. Within the mailer, the face mask resides in a tray, preventing them from shifting within the package. 

Additionally, the Flex Mailer is a professional, branded marketing piece that allows the volunteers to receive the face masks with instructions for use and a message from the nonprofit's CEO printed directly on the tray — saving the need for inserting additional instructional or marketing materials into the mailer.


Not only did the client secure a very low postage rate — 78% savings — but also got a completely customized product, inserted and ready for mail (all at the same amount formerly spent for mailing alone).

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