I have had the very same issue with PSA going back a couple of years now.
The following quote is from their website:
"Please Note - All card/ticket issues vary in size. Occasionally, a card/ticket will not fit into the designated holder. If this occurs, it will be placed in a mylar sleeve and put in an over-sized holder. There are also card/ticket issues that PSA's current holders cannot accommodate. Please call Customer Service for more details."
Although I don't personally like the "look" of the mylar sleeve, I don't have a problem with the aforementioned policy. I realize that they don't have a case that will "fit" every card, especially the uncommon ones. For example; E-120 / E-121 American Caramel, 1979-80 & 1983 Kellogg's, 1968 Topps Baseball Game, etc.
I do have a problem when I know that they have a holder that will "fit" a card, but instead of using that holder; they chose to insert the card into a mylar sleeve and use a holder designed for a larger card. Aesthetically, I think that doing this this ruins the entire presentation.
In April of last year, I submitted several PSA-graded cards to be re-encapsulated in the new (at the time) "tamper-proof" holders. One of these cards was a 1911 Sporting Life Hughie Jennings (1st scan below). When I got it back, it was enclosed inside of a mylar sleeve, in a holder designed for a larger card (2nd scan below). I couldn't understand why, if the original card fit into a holder designed for it (and T-206, etc.), why couldn't it now fit into a new "tamper-proof" holder designed for it. After numerous e-mails back-and forth with the manager, I never received a satisfactory response.
A few months later, I hand-delivered a batch of 13 PSA-graded cards to their Woodbridge, NJ office. I also wanted these cards re-encapsulated in the newer holders. All of these cards were in (old-style) PSA holders that fit them perfectly - none of these cards were enclosed in a mylar sleeve and no mylar sleeves were required. On the submission form, I wrote: "I DO NOT WANT ANY CARD ENCAPSULATED IN A MYLAR SLEEVE. IF THIS IS NON-NEGOTIABLE, PLEASE RETURN THE CARD TO ME (IN ORIGINAL CASE) AND REFUND MY $7.00." These instructions were also verbally reviewed with the PSA representative, who took a highlighter marker and highlighted the aforementioned instructions. I don't think that my request was unreasonable. However, when I received the 13 re-encapsulated cards in the mail, I found that 4 of the cards were enclosed in mylar sleeves; contrary to my written (and verbal) instructions.
After numerous e-mails back-and-forth, this was the final response that I received via e-mail:
"I understand why you dislike the Mylar Sleeves and respectfully saying, I think you have a right to request certain specific, aesthetic arrangements with your cards, to a certain extent........PSA places cards in Mylar Sleeves to preserve the grade of the card if we feel it may shift inside the holder. We have many different types of holders but some cards don’t always fit the dimensions. We are required to do this as our companies work is based on the grading of cards and thus, the preservation of that grade within the holder. With that said, we have the right to place a card in a Mylar Sleeve if we feel it is best for the card. Furthermore, with the volume of cards we encapsulate on a daily basis, it is not always feasible to check the notes left for specific instructions about Mylar Sleeve requests. That department works hard to make sure collectibles are preserved and well-maintained inside our holders per our company policy; it is customer service who attempts to meet your request but our sealing department has their own standards to up-hold. With all due respect, we can no longer meet your written request of the non-negotiable return of cards that need a Mylar Sleeve. Once the cards are graded, they will be put into holders without a second thought........I apologize if this is not understandable or upsetting; it is not my intention to push our customer base away."
I just don't get it. It seems like their competition (SGC) has holders that custom-fit most cards, and looks aesthetically nicer than the mylar sleeve in the larger holder that PSA is so fond of.
I really hate the look of the mylar sleeve inside the holder. Am I the only one that feels this way?
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