Royal Mail Theft By Surcharge

Throwaway2

Free Member
Apr 21, 2018
59
1
I've Just found this forum and it's reassuring to read other people are going through what I've been going through.this week I've received no charges but since January I've been recieving a few charges a week mainly Unreadable barcodes and with growing frequency misplaced label charges.
I've managed to get refunds on all misplaced label chargers but not Unreadable barcodes.
My latest attempt they sent me photos of some of my barcodes highlighting faults in red. This seems nonsense to me as they all scan. But I genuinely think they have a problem with the barcodes and they need to be bigger.
I had a few weeks in the past where I didn't receive any surcharges but I was hoping they had suspended surcharges for everyone until they resolve the issues I raised with them. Unfortunately that seems to not be the case if you've still been getting them during August.

Since you were getting "label applied incorrectly" surcharges and presumably had enough proof to argue against them: are your boxes cubes or tubular, i.e. do they have 4 or 6 equal sides? Because something I realised while writing out my case is that Royal Mail seems to have designed their scan tunnels and surcharge structure on the assumption that boxes have only 2 largest sides. I think for us this might have been the real issue all along and "print quality" might have been a red herring.

I received an update today just saying they're still working on my case and haven't forgotten about it. I still haven't received a credit for anything.
 
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Adamm

Free Member
Aug 28, 2025
12
0
I had a few weeks in the past where I didn't receive any surcharges but I was hoping they had suspended surcharges for everyone until they resolve the issues I raised with them. Unfortunately that seems to not be the case if you've still been getting them during August.

Since you were getting "label applied incorrectly" surcharges and presumably had enough proof to argue against them: are your boxes cubes or tubular, i.e. do they have 4 or 6 equal sides? Because something I realised while writing out my case is that Royal Mail seems to have designed their scan tunnels and surcharge structure on the assumption that boxes have only 2 largest sides. I think for us this might have been the real issue all along and "print quality" might have been a red herring.

I received an update today just saying they're still working on my case and haven't forgotten about it. I still haven't received a credit for anything.
I send in white bubble wrap envelopes and
Several different uniformed sized boxes with clear largest size.
The smallest being 6x4x4.

I thought it would be the envelopes causing problems but when I've asked for photos it's always boxes.
But I had a visit from an area manager earlier in the year to check my packing and he later found out the charges were meant to be Unreadable barcodes and the wrong code was applied.
By the way he couldn't see any problems with my labels and further down the line sent me a forensic report showing magnified issues like thick lines and blobs.
Which Frankly was nonsense.
Honestly I think they have issues with the barcodes not being fit for purpose.
They use the smallest QR codes I've seen.
 
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Talktime

Free Member
Business Listing
Jul 19, 2016
153
31
London
www.nationalbailiffadvice.uk
I'm livid. Royal Mail have recently introduced additional surcharges for items such as 'unreadable barcode' and 'incorrectly applied label'. We take extreme care when labeling our packages, there isn't a chance that our barcodes are 'unreadable', and what even constitutes an 'incorrectly applied label'??! Surely the label is either there or it's not?? We use Royal Mail supplied label stock and a Royal Mail recommended thermal printer. I've disputed each of these surcharges, there appears to be 1 of each per weekly invoice at the moment, with an additional 'administration surcharge' for the 'privilege' of being surcharged. Initially, the response from Royal Mail was that the surcharge had been incorrectly applied and would be credited, they're now dismissing our disputes.

Royal Mail have the gumption to forward their guide to labeling correctly along with their dispute rejection email. We've been doing this for over 20 years, I believe we know how to print and apply a label. The obvious observation is that any loss or damage to labels occurs after the the packages have been taken and mishandled by Royal Mail, we should be compensated - not penalised! I would urge anyone reading this to check the last page of their invoice carefully and dispute ANY and ALL surcharges, other than green surcharge which is unavoidable.

Conveniently, Royal Mail are only occasionally able to provide poor quality photographic evidence of the package and label AFTER they've re-labelled it - curiously, it appears to be identical to the original label we'd originally used. I need to see the 'damage' please Royal Mail, so that I can work to prevent it in future.

I hope every other business hit with these unjustified surcharges is disputing them and will continue to do so. Royal Mail will be bringing in many thousands in revenue from what, without proof, is essentially theft.
Cheers
Your concern is well founded. The surcharges that Royal Mail are now imposing must be considered against the background of the contractual and statutory framework under which they operate. When a business contracts with Royal Mail, the terms of service are governed by their published schemes made under the Postal Services Act 2000, which constitute statutory instruments and have the force of law. These schemes must comply with the requirements of fairness under the Consumer Rights Act 2015 and, where applicable, the Unfair Contract Terms Act 1977, and cannot be enforced in a manner that amounts to an unreasonable exercise of contractual discretion.


In your case, Royal Mail appear to be levying surcharges for alleged “unreadable barcodes” and “incorrectly applied labels” without providing contemporaneous evidence of any defect at the point of handover. As you correctly observe, if the label is clear and legible when it leaves your possession, any degradation or damage that renders it “unreadable” will most likely occur after Royal Mail have assumed custody. In such circumstances, it is not consistent with principle to penalise the sender for the mishandling of items by the carrier. The common law imposes upon a contracting party an implied term to exercise reasonable care and skill in the performance of the service (see section 49 of the Consumer Rights Act 2015). To levy an additional charge for the consequences of its own mishandling is, on its face, a breach of that duty.


Royal Mail’s ability to impose surcharges must also be considered in light of the doctrine against penalties. Although the doctrine is traditionally concerned with clauses triggered by breach, the Supreme Court in Cavendish Square Holding BV v Makdessi [2015] UKSC 67 confirmed that clauses which operate to impose charges out of all proportion to any legitimate commercial interest may be unenforceable. A charge that is triggered by alleged mislabelling, in circumstances where the sender has used Royal Mail approved labels and printers, and where Royal Mail fail to produce adequate proof of fault, may fall within the class of clauses that are penal and therefore unenforceable.


Your further point about photographic evidence is important. If Royal Mail are only able to provide indistinct or post-factum photographs after relabelling, then they are not satisfying the evidential burden of showing that the surcharge was properly applied. The burden rests upon them to justify the charge; otherwise, any sum extracted without proper basis may amount to unjust enrichment, for which restitution would lie. It is no answer for Royal Mail to dismiss disputes with generic references to their labelling guides, particularly where you have demonstrated long-standing compliance.


The remedies available to you are threefold. First, you are entitled to pursue Royal Mail’s internal dispute procedure to exhaustion, but you should do so while making clear that you reserve all legal rights. Secondly, you may escalate the matter to the Postal Review Panel and, if necessary, to Ofcom, who regulate postal operators under the Communications Act 2003 and have powers to investigate systemic unfair practices. Thirdly, you have a direct cause of action in the County Court for restitution of the surcharges already paid and a declaration that the charging practice is unenforceable. The claim would be brought as a civil debt or unjust enrichment claim, and the relevant procedural rules are contained in CPR Part 7.


It is also worth noting that a business which imposes systematic surcharges without proper contractual or statutory justification may be vulnerable to collective action or a representative claim under CPR 19.8, especially where the sums extracted from multiple businesses are relatively small but cumulatively very large. Your instinct that these surcharges are a form of hidden revenue raising is not without legal foundation, and the courts are slow to permit large commercial entities to use standard-form terms to shift the risk of their own failures onto customers without clear justification.


In practical terms, I would advise that you continue disputing each surcharge in writing, demanding strict proof of the alleged defect with contemporaneous evidence, and reserve your rights to bring proceedings. Keep a detailed record of all correspondence. Should Royal Mail fail to credit the surcharges, you would be entitled to issue a small claim for their recovery, and in the course of that litigation Royal Mail would be compelled to disclose their internal guidance, evidence standards, and data concerning the incidence of such charges. That exercise alone is likely to prove highly uncomfortable for them.


The most effective strategy is therefore to maintain pressure through formal dispute and regulatory escalation, while preparing the ground for a small claim or representative action. This combination maximises your leverage and significantly increases the prospect of a settlement or a change in Royal Mail’s charging practices.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
The smallest being 6x4x4.
Bingo. Kite Packaging CSW060404 boxes?

They account for a huge percentage of our surcharges. Nearly every example photo I used in my case was a 6x4x4 box which is when I realised that maybe Royal Mail has a problem with boxes with 4 or 6 equal sides. Or maybe their machines are miscalibrated which is mostly affecting smaller parcels (a few photos I received show a curvature which looks similar to an example of focus miscalibration on page 249 of the AV7000 manual).

Only a handful of surcharges we've received have been related to bubble envelopes and they looked pretty crumpled so I can believe they were maybe unscannable.
 
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Mik W

Free Member
Jul 17, 2025
9
2
Result

After putting up with unreadable bar codes since February we now have a result.
As a recap, we were suddenly hit with charges as soon as they started claiming the codes couldn't be read by their machine in February.
We were getting up to 40 or 50 out of 350 some weeks at a £1 a time as well as wrong format charges.
Most of the wrong format charges got refunded when we asked for proof.
They insisted they could not read the bar codes even though they had generated the bar codes and were claiming our prints were of poor quality.
We were printing their codes on their labels using their recommended printer.

Around Easter time, to prove a point, we started laser printing them. This made no difference whatsoever.
So clearly thermal printing wasn't the issue.
Every week we were being charged and every week we asked for proof and every week proof was not available.
We were getting nowhere, should we go to small claims court?
Meantime we asked for this to be escalated.
We waited several weeks and after reminding them aa couple of times we got an apology for them taking so long to investigate. We got a full refund of every IPROL charge since February with assurance that there would be no more.
They also confirmed that thermal printing was their preferred method.
So back to thermal and 3 weeks and 3 invoices in and we haven't had a single surcharge for anything other than the compulsory ones.
My advise is, collect your evidence of no proof for some time than ask for your case to be escalated.
Can't promised but maybe
 
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Adamm

Free Member
Aug 28, 2025
12
0
Bingo. Kite Packaging CSW060404 boxes?

They account for a huge percentage of our surcharges. Nearly every example photo I used in my case was a 6x4x4 box which is when I realised that maybe Royal Mail has a problem with boxes with 4 or 6 equal sides. Or maybe their machines are miscalibrated which is mostly affecting smaller parcels (a few photos I received show a curvature which looks similar to an example of focus miscalibration on page 249 of the AV7000 manual).

Only a handful of surcharges we've received have been related to bubble envelopes and they looked pretty crumpled so I can believe they were maybe unscannable.
Yeah kite packaging.
I've also argued with them that when I pointed out that if I took my custom elsewhere they would loose a considerable chunk of money. Obviously a drop in the ocean for them but still a sum you wouldn't want to lose.( That's when I had a regional manager sent out to me)
They replied that everyone is treated the same.
I pointed out that This isn't true and only business account customers are treated This way and private customers don't receive additional charges.
They had no answer to this.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
Yeah kite packaging.
I've also argued with them that when I pointed out that if I took my custom elsewhere they would loose a considerable chunk of money. Obviously a drop in the ocean for them but still a sum you wouldn't want to lose.( That's when I had a regional manager sent out to me)
They replied that everyone is treated the same.
I pointed out that This isn't true and only business account customers are treated This way and private customers don't receive additional charges.
They had no answer to this.
One of the very first things I asked Finance is if they have trouble with certain box sizes and they confidently said "no" and that they can handle all sizes allowed by the rate cards.

Royal Mail doesn't publish a minimum size for domestic mail but they do for international which is 140mm x 90mm for letters and 148mm x 105mm for parcels (no thickness specified for either). The 6x4x4 Kite boxes are 151mm x 109mm when I measured them with callipers.

So we're covered if Royal Mail wants to accuse us of sending boxes that are too small.

Royal Mail have possibly three problems as far as I can infer:

1) They are using linear scanners which requires the conveyor to be very smooth and consistent and we can see from many photos that it's not as they have rolling shutter distortions. If any distortions intersect with a barcode it's likely to become unscannable.

2) We can see from the pip_download zip files they provide and the metadata in the images that they only appear to have two Datalogic AV7000s in their parcel scan tunnels. Yet Datalogic themselves say they need 6+ to cover all sides of a parcel. These scanners cost like £20k each and Royal Mail has decided to try and get away with a cheap £40k setup instead of the full £120k setup. To compensate for the shortage of scanners Royal Mail requires customers to only stick the label on the 2 biggest sides of a parcel and if you don't do that they will surcharge you for "label incorrectly applied". But whoever came up with this idea seems to have forgotten that some boxes have 4 or 6 largest sides and even if everything is done perfectly they may get ejected from the machine and surcharged. Whether it's an "unreadable barcode" or "label incorrectly applied" surcharge would be an arbitrary decision by the staff on duty (which lines up with what your area manager also said).

3) This one I'm less sure of. The AV7000s use a proximity sensor to detect the edge of a parcel and when to change focus. In the manual it shows that if this sensor isn't calibrated properly then the change of focus can happen at the wrong time and cause distortions. On a big parcel with the label in the centre this might not be a problem but on smaller parcels where the label is close to the edge then even a small miscalibration could prevent a good scan.
 
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Adamm

Free Member
Aug 28, 2025
12
0
One of the very first things I asked Finance is if they have trouble with certain box sizes and they confidently said "no" and that they can handle all sizes allowed by the rate cards.

Royal Mail doesn't publish a minimum size for domestic mail but they do for international which is 140mm x 90mm for letters and 148mm x 105mm for parcels (no thickness specified for either). The 6x4x4 Kite boxes are 151mm x 109mm when I measured them with callipers.

So we're covered if Royal Mail wants to accuse us of sending boxes that are too small.

Royal Mail have possibly three problems as far as I can infer:

1) They are using linear scanners which requires the conveyor to be very smooth and consistent and we can see from many photos that it's not as they have rolling shutter distortions. If any distortions intersect with a barcode it's likely to become unscannable.

2) We can see from the pip_download zip files they provide and the metadata in the images that they only appear to have two Datalogic AV7000s in their parcel scan tunnels. Yet Datalogic themselves say they need 6+ to cover all sides of a parcel. These scanners cost like £20k each and Royal Mail has decided to try and get away with a cheap £40k setup instead of the full £120k setup. To compensate for the shortage of scanners Royal Mail requires customers to only stick the label on the 2 biggest sides of a parcel and if you don't do that they will surcharge you for "label incorrectly applied". But whoever came up with this idea seems to have forgotten that some boxes have 4 or 6 largest sides and even if everything is done perfectly they may get ejected from the machine and surcharged. Whether it's an "unreadable barcode" or "label incorrectly applied" surcharge would be an arbitrary decision by the staff on duty (which lines up with what your area manager also said).

3) This one I'm less sure of. The AV7000s use a proximity sensor to detect the edge of a parcel and when to change focus. In the manual it shows that if this sensor isn't calibrated properly then the change of focus can happen at the wrong time and cause distortions. On a big parcel with the label in the centre this might not be a problem but on smaller parcels where the label is close to the edge then even a small miscalibration could prevent a good scan.
The other issue which clearly isn't happening despite them saying it is,the rejected labels are not being manually scanned after.
I've argued they can't be being checked by a person but they insist they are.
Surely if they were being manually checked we wouldn't be having these issues.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
The other issue which clearly isn't happening despite them saying it is,the rejected labels are not being manually scanned after.
I've argued they can't be being checked by a person but they insist they are.
Surely if they were being manually checked we wouldn't be having these issues.
They never claimed that with me.

They seem to make up any nonsense on the spot, like a child making up excuses. As you can see in this thread we've all been told different stories to try and make us give up and go away.
 
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Adamm

Free Member
Aug 28, 2025
12
0
They never claimed that with me.

They seem to make up any nonsense on the spot, like a child making up excuses. As you can see in this thread we've all been told different stories to try and make us give up and go away.
I just don't understand how you can treat customers that you are relying on to keep them afloat like this.
They should be bending over backwards to keep us and not treating us like kids in school.If I wasn't locked to large letters I would have moved elsewhere by now.
I've had problems with every part of their business From account set up to deliveries.
Some of the stuff I've been through has been laughable.
And now you can't even speak to them.
It takes weeks to get a reply.
Even the business complaints email is now taking weeks to respond.
It's a shambles.
 
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Adamm

Free Member
Aug 28, 2025
12
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They never claimed that with me.

They seem to make up any nonsense on the spot, like a child making up excuses. As you can see in this thread we've all been told different stories to try and make us give up and go away.
This is the latest response I've received when pushing for evidence and an explanation. As yet I've still not been refunded for any Unreadable label charges.
My latest invoice has had a spike in Unreadable charges and incorrect format charges have appeared on the last 2 invoices.

'We will provide images for charges related to Label Incorrectly Applied and Unreadable Barcodes, where possible. However, when our machine technology cannot read a label effectively, capturing a useful image may not be possible. Importantly, any item processed for either of these charges undergoes manual over labelling at a workstation within our Mail Centre, following its initial rejection by our automated technology. While we strive to provide images whenever we can, the charge's validity is confirmed through this secondary, manual verification process and images are not a requirement to validate the charges.

Only 0.3% of items at our mail centres are over-labelled due to Unreadable Barcodes. Our machines are highly accurate and continuously monitored by our engineering teams to spot and address any readability issues.

When our machines cannot read the barcode, the images are sent to our central computer for a further read attempt and to assess whether the label should be over-labelled. This provides us with a high degree of confidence in our decisions.

I can confirm these are accurate charges which were raised in line with our Terms and conditions | Royal Mail, any applicable Surcharges & the Welcome to our UK Parcel services user guide (March 2025) , which is a legally binding document forming part of the agreement between you and Royal Mail.

I understand that this will not be the response you were hoping for, but please feel assured your case has been investigated and your charges remain.'
 
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Mik W

Free Member
Jul 17, 2025
9
2
This is the latest response I've received when pushing for evidence and an explanation. As yet I've still not been refunded for any Unreadable label charges.
My latest invoice has had a spike in Unreadable charges and incorrect format charges have appeared on the last 2 invoices.

'We will provide images for charges related to Label Incorrectly Applied and Unreadable Barcodes, where possible. However, when our machine technology cannot read a label effectively, capturing a useful image may not be possible. Importantly, any item processed for either of these charges undergoes manual over labelling at a workstation within our Mail Centre, following its initial rejection by our automated technology. While we strive to provide images whenever we can, the charge's validity is confirmed through this secondary, manual verification process and images are not a requirement to validate the charges.

Only 0.3% of items at our mail centres are over-labelled due to Unreadable Barcodes. Our machines are highly accurate and continuously monitored by our engineering teams to spot and address any readability issues.

When our machines cannot read the barcode, the images are sent to our central computer for a further read attempt and to assess whether the label should be over-labelled. This provides us with a high degree of confidence in our decisions.

I can confirm these are accurate charges which were raised in line with our Terms and conditions | Royal Mail, any applicable Surcharges & the Welcome to our UK Parcel services user guide (March 2025) , which is a legally binding document forming part of the agreement between you and Royal Mail.

I understand that this will not be the response you were hoping for, but please feel assured your case has been investigated and your charges remain.'
You will receive this same response every time. When you have say 10 or more you need to escalate it
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
I've now received a credit for about 3/4 of our surcharges. It seems like they only calculated back to April instead of all the way back to January. They've also over refunded us VAT as they didn't take into account that international labels and their surcharges are zero rated. I've asked them for a correction.

The reason I know they've short changed us is because I had already gone through every invoice and counted all the surcharges and graphed them out looking for patterns. It doesn't take long, especially if your email client can search inside PDFs (e.g. Gmail), so everyone should do the same to make sure you get the full refund amount.
 
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Adamm

Free Member
Aug 28, 2025
12
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I've now received a credit for about 3/4 of our surcharges. It seems like they only calculated back to April instead of all the way back to January. They've also over refunded us VAT as they didn't take into account that international labels and their surcharges are zero rated. I've asked them for a correction.

The reason I know they've short changed us is because I had already gone through every invoice and counted all the surcharges and graphed them out looking for patterns. It doesn't take long, especially if your email client can search inside PDFs (e.g. Gmail), so everyone should do the same to make sure you get the full refund amount.
That's quite an achievement nice work.
Are you still not getting any new charges?

Could you do a quick summary of the steps you went through to achieve this ?

Don't worry if you don't want to I know you've posted a lot of info .
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
That's quite an achievement nice work.
Are you still not getting any new charges?

Could you do a quick summary of the steps you went through to achieve this ?

Don't worry if you don't want to I know you've posted a lot of info .
I had a unique situation in that I've done open source development in the past with thermal printers, barcode scanners, etc so I was very confident when Royal Mail were BSing me. I also still had contact points with Royal Mail's development teams.

What I did was:

1) Open a surcharge dispute every invoice requesting the spreadsheet of barcodes and as many photos as possible.

2) If they don't say on the first reply, get them to explain what is wrong with your labels. 99% of the time their explanation will be nonsense and you can keep pushing them on it and trap them into making up more and more stupid excuses. But it's really important that you actually know your stuff, don't argue with them just because you are angry about the money (I actually spent money during this process, £260 servicing our printers). The 1% of time they are right e.g. a damaged or crumped package, don't waste time arguing over who damaged the package, just drop that case and focus on the others.

3) If you have a good account manager, others have said that once you have enough evidence you will be able to ask them to escalate or send someone out to check your labels and then escalate. Unfortunately our account manager was useless and unresponsive.

4) In the meantime I was also in contact with another Royal Mail team in regards to a bug with one of their APIs. They fixed that bug but were curious about why our labels were apparently failing to scan and thought there might be another problem.

5) We sent in labels to Royal Mail to be tested with their machines and we passed.

6) Finance then accused the other Royal Mail team of doing their job badly and not testing our labels properly. I think this proved to them how crazy Finance are and this other team escalated the case for me.

7) For the escalation team I created a 35 page, 4400 word document with tens of pictures and examples explaining how thermal printers, barcode scanners, etc work and then destroyed all the claims Finance had made in steps 1 and 2.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
That's quite an achievement nice work.
Are you still not getting any new charges?

Could you do a quick summary of the steps you went through to achieve this ?

Don't worry if you don't want to I know you've posted a lot of info .
Also, no, we haven't received any new surcharges since it was escalated at the start of August.

I doubt they have improved the process at mail centres. I think they can just block surcharges from being billed to certain accounts. Someone else earlier in the thread said the same thing happened to them.
 
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Adamm

Free Member
Aug 28, 2025
12
0
I had a unique situation in that I've done open source development in the past with thermal printers, barcode scanners, etc so I was very confident when Royal Mail were BSing me. I also still had contact points with Royal Mail's development teams.

What I did was:

1) Open a surcharge dispute every invoice requesting the spreadsheet of barcodes and as many photos as possible.

2) If they don't say on the first reply, get them to explain what is wrong with your labels. 99% of the time their explanation will be nonsense and you can keep pushing them on it and trap them into making up more and more stupid excuses. But it's really important that you actually know your stuff, don't argue with them just because you are angry about the money (I actually spent money during this process, £260 servicing our printers). The 1% of time they are right e.g. a damaged or crumped package, don't waste time arguing over who damaged the package, just drop that case and focus on the others.

3) If you have a good account manager, others have said that once you have enough evidence you will be able to ask them to escalate or send someone out to check your labels and then escalate. Unfortunately our account manager was useless and unresponsive.

4) In the meantime I was also in contact with another Royal Mail team in regards to a bug with one of their APIs. They fixed that bug but were curious about why our labels were apparently failing to scan and thought there might be another problem.

5) We sent in labels to Royal Mail to be tested with their machines and we passed.

6) Finance then accused the other Royal Mail team of doing their job badly and not testing our labels properly. I think this proved to them how crazy Finance are and this other team escalated the case for me.

7) For the escalation team I created a 35 page, 4400 word document with tens of pictures and examples explaining how thermal printers, barcode scanners, etc work and then destroyed all the claims Finance had made in steps 1 and 2.
Thanks.
you really have had to work hard for it.
Well done

My big issue is I can't even discuss it with them anymore. They just stop replying after the first or second response.
Or weeks go between responses.
Very frustrating.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
Thanks.
you really have had to work hard for it.
Well done

My big issue is I can't even discuss it with them anymore. They just stop replying after the first or second response.
Or weeks go between responses.
Very frustrating.
They were the same for me. Open a new dispute for every invoice and they will always reply in 1-2 weeks with 2-4 photos, sometimes with lines drawn on them pointing out nonsense. So depending on how regularly you receive invoices you can slowly build up evidence.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
I finally got a credit for everything, actually a little bit extra because they couldn't find the same number as surcharges in their system as I counted from invoices so they also refunded an unrelated admin charge from something else. And they still did the VAT wrong on surcharges relating to international labels.

It's taken me 102 days from first noticing these surcharges to stopping them and getting a full credit.
 
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Adamm

Free Member
Aug 28, 2025
12
0
I finally got a credit for everything, actually a little bit extra because they couldn't find the same number as surcharges in their system as I counted from invoices so they also refunded an unrelated admin charge from something else. And they still did the VAT wrong on surcharges relating to international labels.

It's taken me 102 days from first noticing these surcharges to stopping them and getting a full credit.
Huge congratulations.
I wish I had the knowhow You've got to have thought this. Very well done.

My problems seem to be getting worse.
They've stopped refunding my incorrect format now even though I'm sending proof of the items fitting through a large letter guide. They even said air getting in the packet could cause a charge!
And the unreadable barcodes I'm getting no joy.
They seem Very reluctant to reply and just cut off replying after a few emails.
I asked to escalate it and got a blank email in return.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
Huge congratulations.
I wish I had the knowhow You've got to have thought this. Very well done.

My problems seem to be getting worse.
They've stopped refunding my incorrect format now even though I'm sending proof of the items fitting through a large letter guide. They even said air getting in the packet could cause a charge!
And the unreadable barcodes I'm getting no joy.
They seem Very reluctant to reply and just cut off replying after a few emails.
I asked to escalate it and got a blank email in return.
Don't conflate the new unreadable barcode surcharges with the older and well established surcharges like incorrect format, weight, etc.

They have evidence of incorrect format etc. If it's multiple items stacked on top of each other they will refund you no questions asked. If it's a soft envelope getting deformed or filling with air it will show on the photo and they won't refund you. You can disagree with them but they are predictable rules. You should adjust your packaging to work with them and you will stop getting surcharges.

The reason people are mad about the new unreadable barcode surcharges is because 99% of the time there is no evidence and there's nothing we can do on our side to stop them.

Mixing the two type of surcharges together won't help your case and will make Royal Mail more dismissive of everyone who complains.
 
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kevinHit

Free Member
Jun 16, 2025
30
1
I finally got a credit for everything, actually a little bit extra because they couldn't find the same number as surcharges in their system as I counted from invoices so they also refunded an unrelated admin charge from something else. And they still did the VAT wrong on surcharges relating to international labels.

It's taken me 102 days from first noticing these surcharges to stopping them and getting a full credit.
Good to hear that others have managed to win this -- we have not had any further IPROL surcharges since they credited us.

I can see you went to lot more effort than I did with your defence with Royal Mail "created a 35 page, 4400 word document with tens of pictures and examples explaining how thermal printers, barcode scanners, etc work"

When I escalated, I only provided them with handful of barcodes that I had deliberately damaged that still scanned perfectly and advised that there Innovation Team and the makers of the PSMs can verify my statements. I also (paraphrasing) told them that all barcodes scanned when they left us, if the barcodes did not scan they could only have been damaged whilst in the care of Royal Mail.
 
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Proletariat22

Free Member
May 15, 2024
6
1
I'm livid. Royal Mail have recently introduced additional surcharges for items such as 'unreadable barcode' and 'incorrectly applied label'. We take extreme care when labeling our packages, there isn't a chance that our barcodes are 'unreadable', and what even constitutes an 'incorrectly applied label'??! Surely the label is either there or it's not?? We use Royal Mail supplied label stock and a Royal Mail recommended thermal printer. I've disputed each of these surcharges, there appears to be 1 of each per weekly invoice at the moment, with an additional 'administration surcharge' for the 'privilege' of being surcharged. Initially, the response from Royal Mail was that the surcharge had been incorrectly applied and would be credited, they're now dismissing our disputes.

Royal Mail have the gumption to forward their guide to labeling correctly along with their dispute rejection email. We've been doing this for over 20 years, I believe we know how to print and apply a label. The obvious observation is that any loss or damage to labels occurs after the the packages have been taken and mishandled by Royal Mail, we should be compensated - not penalised! I would urge anyone reading this to check the last page of their invoice carefully and dispute ANY and ALL surcharges, other than green surcharge which is unavoidable.

Conveniently, Royal Mail are only occasionally able to provide poor quality photographic evidence of the package and label AFTER they've re-labelled it - curiously, it appears to be identical to the original label we'd originally used. I need to see the 'damage' please Royal Mail, so that I can work to prevent it in future.

I hope every other business hit with these unjustified surcharges is disputing them and will continue to do so. Royal Mail will be bringing in many thousands in revenue from what, without proof, is essentially theft.
Cheers
I have been sending an item as a Large Letter through Click & Drop for years without issue. All of a sudden in the last couple of months I have been receiving surcharges due to ‘misdeclared’ items , as well as an ‘admin fee’ and of course the nonsense green and fuel surcharges. I have also seen several other OBA users that have seen an increase in surcharges - whether it’s ’unreadable barcode’ that is clearly ready or false weight charges so this isn’t a coincidence. RM are unfairly charging people, making it near impossible to get a refund and it seems like there is nothing we can do about it . Definitely something that needs to be investigated.
 
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crafting_bee

Free Member
Oct 2, 2025
1
0
I've been having the same problem as everyone else and I've tried literally everything to resolve this. I'm getting about 20 of these barcode charges every week. I've been through the same process as everyone else, even having a service field manager come out and say I'm doing everything perfectly and there are no issues with the barcodes.

The most annoying part of this, is not being able to fix the issue and stop the charges, unlike all of the other surcharge types.

I have made 2 observations:
  1. When I buy a one-off postage label through the Royal Mail website, the label has a much larger/simpler 2D barcode - which always prints perfectly because of the size. The Click and Drop business account prints much smaller/detailed 2D barcodes, and it doesn't always print perfect squares because they are SO tiny (the RM manager that came out said that still doesn't make it unscannable unless they have faulty scanners).
  2. I've worked out that on average, the barcode charges equate to almost the exact difference in my contract price per item and the retail cost per item - funny that!
Has anyone else managed to put a stop to these charges? I've tried everything that everyone has suggested :(

I hope a journalist reads this at some point and speaks up for us small business owners!
 
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Mik W

Free Member
Jul 17, 2025
9
2
I've been having the same problem as everyone else and I've tried literally everything to resolve this. I'm getting about 20 of these barcode charges every week. I've been through the same process as everyone else, even having a service field manager come out and say I'm doing everything perfectly and there are no issues with the barcodes.

The most annoying part of this, is not being able to fix the issue and stop the charges, unlike all of the other surcharge types.

I have made 2 observations:
  1. When I buy a one-off postage label through the Royal Mail website, the label has a much larger/simpler 2D barcode - which always prints perfectly because of the size. The Click and Drop business account prints much smaller/detailed 2D barcodes, and it doesn't always print perfect squares because they are SO tiny (the RM manager that came out said that still doesn't make it unscannable unless they have faulty scanners).
  2. I've worked out that on average, the barcode charges equate to almost the exact difference in my contract price per item and the retail cost per item - funny that!
Has anyone else managed to put a stop to these charges? I've tried everything that everyone has suggested :(

I hope a journalist reads this at some point and speaks up for us small business owners!

I've been having the same problem as everyone else and I've tried literally everything to resolve this. I'm getting about 20 of these barcode charges every week. I've been through the same process as everyone else, even having a service field manager come out and say I'm doing everything perfectly and there are no issues with the barcodes.

The most annoying part of this, is not being able to fix the issue and stop the charges, unlike all of the other surcharge types.

I have made 2 observations:
  1. When I buy a one-off postage label through the Royal Mail website, the label has a much larger/simpler 2D barcode - which always prints perfectly because of the size. The Click and Drop business account prints much smaller/detailed 2D barcodes, and it doesn't always print perfect squares because they are SO tiny (the RM manager that came out said that still doesn't make it unscannable unless they have faulty scanners).
  2. I've worked out that on average, the barcode charges equate to almost the exact difference in my contract price per item and the retail cost per item - funny that!
Has anyone else managed to put a stop to these charges? I've tried everything that everyone has suggested :(

I hope a journalist reads this at some point and speaks up for us small business owners!

Challenge every charge, you will get the same nonsense reply.
Escalate it when you have plenty
 
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Adamm

Free Member
Aug 28, 2025
12
0
An update on mine.
I haven't had any surcharges for the last 2 invoices. I'm Not sure if this is luck or they've put a hold on them for my account.
I've not had any responses about my escalation requests, so time will tell I guess.

Another annoying thing is I've just had my contract review and all of my prices are going up roughly 8% And I've done way above my posting profile.
 
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Adamm

Free Member
Aug 28, 2025
12
0
A further update.
I've just received a response from my escalation requests and they have offered me a credit for all the charges since January as a GOODWILL GESTURE.
they still haven't accepted that the charges were wrong or admitted fault and still refer me to the best practice guide.

I'm happy to get the money back but this doesn't seem to cover anything about future charges.

Those who have received refunds previously did they admit fault at all?
 
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Adamm

Free Member
Aug 28, 2025
12
0
My charges for Unreadable labels have started again,I suspect the block to these charges has been removed.
has this happened to anyone else?
But the biggest change is That Royal mail are now replying to the query with a no reply email address. You can't even respond to their rejection response now.
 
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Throwaway2

Free Member
Apr 21, 2018
59
1
Just checking in. We still haven't had any surcharges since July so our block is still holding. I'm worried though that Royal Mail still sneak them back in somewhere else and I won't spot them until months later.

I thought maybe Royal Mail had improved things and the issue had quietened down but over on Reddit there's been a bunch of new people reporting the issue in the last 2 months. We got a new account manager in October and she visited and said others are having the same issue and that I'm the only person she knows who has beaten it.

I'm still waiting to see if anyone does take legal action or if a reliable reporter picks it up. I believe I showed Royal Mail ample evidence of problems with their machines/procedures so I don't see how management could claim ignorance.
 
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Newchodge

Moderator
  • Business Listing
    Nov 8, 2012
    22,634
    8
    7,948
    Newcastle
    Just checking in. We still haven't had any surcharges since July so our block is still holding. I'm worried though that Royal Mail still sneak them back in somewhere else and I won't spot them until months later.

    I thought maybe Royal Mail had improved things and the issue had quietened down but over on Reddit there's been a bunch of new people reporting the issue in the last 2 months. We got a new account manager in October and she visited and said others are having the same issue and that I'm the only person she knows who has beaten it.

    I'm still waiting to see if anyone does take legal action or if a reliable reporter picks it up. I believe I showed Royal Mail ample evidence of problems with their machines/procedures so I don't see how management could claim ignorance.
    I reckon it would be worth talking to your MP (depending who they are), as it was only the MP involvement that really got the Post Office/Horizon scandal recognised.
     
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    Throwaway2

    Free Member
    Apr 21, 2018
    59
    1
    I reckon it would be worth talking to your MP (depending who they are), as it was only the MP involvement that really got the Post Office/Horizon scandal recognised.
    From my perspective Royal Mail did me right in the end and I don't know if anyone else is truly being wrongly surcharged or if they're just whining about having to pay extra for real errors they made.

    There's no material gain for me inflicting the drama of the media on myself. If someone else does then I may pass along my evidence.

    For example...

    About two years ago I bought some parts for blinds online and they took two weeks to arrive, probably because the label had been printed on the most clapped out laser printer I have ever seen, very faded, and clearly a bit of tape or something stuck to the drum. One of the parts I had ordered was missing so I emailed the shop asking for it and also requested that they print a better label so that I don't have to wait another two weeks. Commence them going off on me saying there was nothing wrong with their printer and it doesn't matter how faded their labels are because barcodes are binary and either scan or don't blah blah etc. So I know for sure there are some idiots out there who deserve the surcharges.
     
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    Rob-Ed

    Free Member
    Apr 28, 2009
    77
    5
    Having queried plenty of 'unreadable barcode' surcharges now and having had the first few refunded as 'incorrectly applied', we are no longer refunded for ANY queries, 'correctly applied'. I don't know what's changed.
    Regarding Kite 6 x 4 x 4 inch boxes; we use a lot of these and now always ensure that we do not label ove the taped flaps. We always apply label to the 'flattest' side. This seems to have reduced the number of surcharges.
    A problem occurs when we use a 6 x 5 x 4 inch box, the taped flaps are on the longest/widest face of the box. We either label over the tape (bad idea) or we apply to the smallest box face (bad idea) can't win with this one, both against RM guidelines.
    I'm not aware of any issues with unreadable barcodes when using padded mailing bags (mail lite etc), I'm wondering if RM use more reliable scanning equipment for 'soft' packages.

    Royal Mail claim that they've always performed relabelling for unreadable or misplaced barcodes but that they have never charged for it....until now.

    I'm sure you were all thrilled to learn that Royal Mail have now decided to start charging their customers for thermal labels as well. These postal supplies will no longer be free of charge. They limited customers (or us, anyway) to a maximum of 5 rolls of 6 x 4 thermal labels per order last year. We can't even stock up before they hit us with yet another charge that we weren't subjected to previously. I can sort of understand it as some customers may be using RM supplied labels for non RM shipments, we're not.

    An alternative delivery service, some true competition for the unassailable position that RM was gifted as a private company would be very welcome.
     
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    Throwaway2

    Free Member
    Apr 21, 2018
    59
    1
    6 x 4 x 4
    6 x 5 x 4
    Nearly all of our surcharges were for the 6x4x4 boxes and we always stuck the label on the non-tape side. Our next smallest box is 9x6x4 and I'm not sure if that ever got surcharged, maybe once or twice.

    I am fairly confident, judging by the metadata in the images Royal Mail provides, that they simply forgot about boxes with 4 or 6 equal sides when building their machines and designing the scan tunnels to go with it. I think 6x5x4 is close enough to fall into that too.

    I'm sure you were all thrilled to learn that Royal Mail have now decided to start charging their customers for thermal labels as well.
    I like to keep a good amount of spare rolls so that we don't have a risk of running out. That was no longer possible when they reduced us to 10 and then 5 per order so our account manager said to just place multiple orders at once which is what we've been doing. Stupid on Royal Mail's part as it now cost them more to ship multiple orders instead of a single box of 20.

    Now the mail supplies shop has a warning saying not to do that and that they will only ship one order and any more will be cancelled, so I stopped doing that. But they haven't shipped either of my last two orders and they seem to have cut us off completely.

    I think yet another Royal Mail office worker who has never touched a thermal printer in their life is doing a simple "X parcels shipped * Y labels ordered" calculation and accusing us of ordering too many labels. What they don't realise is the labels are also used for customs and a few on a roll are always lost to feeding them through the printer, jams, etc.
     
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    TBLZ

    Free Member
    Dec 2, 2010
    51
    2
    I came to this post from Googling 'Royal Mail Stealth Charges'

    My weekly bill is now over £1000 and i think that it would only around £400-500 a week a couple of years ago. I do send more Tracked48 and Tracked24 items but still, it's getting out of hand.

    I have noticed that lots of surcharges have been appearing on my invoice, something I have noticed only recently too.

    I get fed up with Royal Mail. They hiked my contract prices again recently and by the time I add all their green surcharges and VAT etc... I am paying more to send Tracked48 than someone can buy it for through the Royal Mail website. When I questioned this, they did drop my price hike considerably but I am still paying more.

    I spend around £35-40k with RM a year anyone of the street gets better prices than I do!

    As the OP also said. The majority of my items are low value and on the cusp of large letter and small parcel.
    Use UPS.
     
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