Phyllis...This is what I've been told.
If the size of the package can not go through the machine it costs extra. They must then sort it manually.
The extra cost then depends on the weight of the package. This why some people like to put chips in envelopes(this should be a no no) and not padded packaging. So 1-2 chips (varies) are $.63 now. Its starts to go up after every oz no matter what the size of the package. It now becomes the weight.
I'm fortunate to have a very nice postal worker too and she knows me to well also. Does this help. I agree with John, I wish I was there to talk to that person. Some of them can be darn right rude, but then again I've seen customers be quite rude too. Not appling us.
Dont know why they go postal, but they do stay very busy.
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