As a seller, this happened to me about 3 years ago where the buyer received a postage due on one of my envelopes. It turned out that the envelope was less than 3/4 inches thick and some postal employee decided to convert it to a Priority mail package.
I always insert 1 styrofoam peanut in every bubble envelope that I ship out. This guarantees that it passes the 3/4 inch test. I never had an issue since then and I mail out several thousand packages a year.
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