Why some postcards arrive smudged or marked?

Short answer: USPS processing can scuff or smudge postcards during high-speed sorting and transport. This is common across the industry and does not indicate a printing defect.

What you might see

• Light gray or black rub marks or streaks

• Scuffing or small scratches on coated areas

• Minor toner lift where rollers made contact

• Inkjet spray or barcodes printed over artwork

• Occasional corner nicks or edge wear

• Rare cases of surface “burn” marks from friction heat

Why it happens

• USPS high-speed sorters use belts, rollers, and metal gates that physically contact each postcard to move and route it. Contact creates friction and can abrade the surface.

• Friction and heat in the mailstream, plus stacking in bins, add minor wear.

• Barcode and cancellation spraying can land on the front image depending on orientation.

What OLC controls

• We print on production-grade digital presses with calibrated color and quality checks per batch.

• We handle, package, and tender mail to USPS following USPS operational standards. Once USPS accepts the mail, it enters its automated network.

What USPS controls

• The end-to-end movement through sorting equipment and carrier handling.

• Local facility calibration and throughput, which can vary by plant and day.

How to reduce visible marks on future campaigns

• Design for the journey. Avoid large solid dark areas in critical spots since rub marks are most visible on heavy coverage. Keep key text away from likely contact paths and barcode zones.

• Allow safe areas. Keep must-read content and CTAs clear of edges and postal indicia zones where equipment engages.

• Consider envelopes for VIP audiences. If pristine presentation is critical, mailing in an envelope protects the piece during processing. Community and practitioner reports support this.