Graphic of the BEP Seal
Bureau of Engraving and Printing
U.S. Department of the Treasury

Pictured below: Shrink-wrapped packages of one dollar notes.
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When an imperfect note is detected during the manufacturing process after the serial number has been overprinted, it must be replaced with a new note. A "star" note is used to replace the imperfect note. Reusing that exact serial number to replace the imperfect note is costly and time consuming. The "star" note has its own special serial number followed by a star in place of a suffix letter.

 

The serial number of the imperfect note that was removed is not used again in the same numbering sequence.