I also read that items shifting around the envelope may cause problems in the machinery. So I also tape the contents to the inside of the envelope
That's a REALLY smart thing to do. I've received a few ACEOs that were in hard plastic toploaders, but loose in the envelope, and they did shift and cause a tear in the envelope.
There are a few people who I collect from, who use the hard plastic toploaders inside a note card, but tape the toploader in place, and those always arrive safely. I always try to make sure that my ACEOs are between cardboard or secured in some manner that they won't slide around. My feeling is, when you package an ACEO, shake the envelope around a little before you mail it. If you can hear anything sliding around inside, then it's not packaged well enough.
Charlie, it's so true about the slightest thing getting caught in the machinery. I have a friend who sends me collectible stickers from his radio station, and he always paper clips them to a piece of note paper, and the paper clip ALWAYS gets caught in the machinery. The machines they use these days will only accept a perfectly flat, evenly proportioned piece of mail.
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Kathy
Kathy