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Thousands of SF mail-in ballots arrive in torn envelopes after USPS machine error

Thousands of SF mail-in ballots arrive in torn envelopes after USPS machine error

Built World San Francisco, CA local

Officials say outer-envelope tears don't affect ballots; USPS switches to hand-sorting remaining packets

Today: SFGate reports thousands of ballots damaged by machine

Overview

Updated 1 hour ago

Thousands of San Francisco voters are finding their mail-in ballot envelopes torn and crumpled when they arrive. The U.S. Postal Service says its sorting equipment caused the damage and has switched to hand-processing the remaining ballot packets for the Nov. 3 election.

Election officials say outer-envelope tears don't affect voting, as long as the four ballot cards and return envelope inside are intact. No inner ballot damage has been confirmed. The department is now monitoring mailings with USPS as the city's 535,787 vote-by-mail packets go out.

Why it matters

Torn envelopes could shake voter confidence in mail-in voting, and any damaged ballot inside could keep a San Franciscan from voting in November.

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Key Indicators

535,787
Vote-by-mail ballots sent to SF voters
More than half a million ballot packets mailed ahead of the Nov. 3 election.
Thousands
Envelopes reported torn
Exact count unknown; USPS calls the affected number 'small' but photographers and voters documented tears citywide.
4
Ballot cards per packet
Voters are told to check for all four cards, the return envelope, and an insert with instructions.
26 days
Days from incident report to Election Day
Oct. 8 to the Nov. 3 election — time for replacements and manual processing of remaining ballots.

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People Involved

Organizations Involved

Timeline

3 events Latest: Today
  1. SFGate reports thousands of ballots damaged by machine

    Today News Report

    Bay Area News reports the Department of Elections will continue monitoring ballot mailings after thousands of envelopes arrive damaged.

  2. Torn envelope reports prompt SF elections advisory

    Statement

    Elections director John Arntz says USPS reported machine-caused tears in outer envelopes. USPS switches to manual processing of remaining ballot packets.

  3. SF begins mailing 535,787 ballot packets

    Infrastructure

    San Francisco Department of Elections mails vote-by-mail packets ahead of the Nov. 3 election. USPS processing equipment begins tearing outer envelopes on some packets.

Scenarios

1

SF certifies Nov. 3 election with no ballots lost to damage

Likely Resolves by Dec 3, 2026

Discussed by: San Francisco Department of Elections director John Arntz, who says all ballots remain usable if inner contents are intact

The tears stay limited to outer envelopes. Voters check their packets, find all four ballot cards and the return envelope undamaged, and vote normally. The department certifies results with no unusual rejection rates and no reported ballot losses tied to the mechanical failure.

2

Multiple SF voters unable to use damaged mail ballots

Possible Resolves by Nov 4, 2026

Discussed by: KQED, which reported at least one voter with a torn inner return envelope; Mission Local, which documented citywide photos of torn packets

Some voters find damage to inner contents — ballot cards or return envelopes — and request replacements from the department. If the damage is widespread enough, voters who don't catch it may have ballots rejected, or may be forced to vote in person on Election Day.

3

USPS election mail handling draws formal review

Unlikely Resolves by Q2 2027

Discussed by: Not currently predicted by any named source; speculative based on national attention to postal election mail reliability

Advocacy groups or elected officials press for investigation into postal equipment damaging election mail. The USPS Office of Inspector General opens a formal review, or Congress holds a hearing on how postal machines handle thick ballot packets.

Historical Context

2 moments from history that rhyme with this story — and how they unfolded.

August 2020

USPS warns states on 2020 ballot delivery (2020)

USPS sent letters to 46 states warning it could not guarantee on-time delivery of mail-in ballots for the November 2020 election, citing operational changes. Postal inspectors later reported worsening on-time delivery rates for first-class mail.

Then

States adjusted ballot deadlines, voters were urged to mail ballots early, and multiple lawsuits sought to restore USPS operational standards before Election Day.

Now

The incident cemented the USPS as a recurring risk factor in election administration and intensified national debate over vote-by-mail reliability.

Why this matters now

Shows USPS operational issues can disrupt election mail — the same vulnerability San Francisco voters are now confronting with torn envelopes.

November 2000

Florida butterfly ballot controversy (2000)

Palm Beach County's butterfly ballot design confused voters, some of whom unintentionally voted for the wrong candidate. The ballot errors helped trigger a statewide recount decided 5-4 by the U.S. Supreme Court.

Then

George W. Bush won Florida by 537 votes and the presidency. Palm Beach County retired the butterfly ballot.

Now

States overhauled ballot design and voting equipment. The episode showed how small ballot flaws can shake confidence in close elections.

Why this matters now

Like today's torn envelopes, a ballot flaw that raises doubts about whether votes count can matter far beyond the mechanics of the error.

Sources

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