Question:
What’s the best way to package chips (by the hundreds) when you don’t have warneke boxes?
There are a few different ways to tackle this without Warneke boxes on hand. If time is of the essence and purchasing and waiting for them to ship isn't an option, the following methods work well:
1) USPS Priority Padded Mailer Method
A USPS Priority Padded Mailer can comfortably fit two barrels laid flat at the bottom. Roll them up tightly and secure them with painter’s tape. Then, place the mailer inside a snug-fitting box, and finally into the main shipping box—whether that's an MFRB, LFRB, or whatever size is most appropriate.
2) No Padded Mailers? Use Saran Wrap + SFRB
If padded mailers aren’t available, tightly wrap the barrels in Saran Wrap and place them inside a Small Flat Rate Box (SFRB). You can safely fit 3 barrels across and 2 barrels high. Add some packing peanuts, bubble wrap, or other cushioning material to prevent movement. For added protection, place the SFRB inside another box.
Painters tape to secure insides, packing tape to securing the PACKAGING. Not sure how many times I can repeat this.