I believe if you check around on the web and look at others selling gourmet desserts, you will find they ship them to their customers frozen. This is how they avoid the issues you bring up. Recently, my wife won a prize of a year`s supply of gourmet desserts - a monthly shipment for 12 months. We just received the first shipment yesterday. A styrofoam container about 20" cube, separateable in a top and bottom half. The product was a pumpkin creme cheese cake - frozen solid as a rock. The bottom half of the container was basically the packing for the cake - surrounded by a cardboard ring with spacers to eliminate the side-to-side movement - tight as socks on a rooster. Then another cardboard plate on top of this entire layer. Then, the top half was for the dry ice - inside a plastic bag. The dry ice was still about the size of a laptop computer when it arrived. We threw the cake in the freezer and will thaw it out for Thanskgiving.
I don`t see how you can ship a fresh cake, not frozen. Even if you could eliminate the side-to-side movement in shipping, you will never be able to guarantee the package will not end up upside-down in transit and no matter what packaging you devise, a fresh cake will not be able to stand that kind of abuse.
Can you not freeze your product fresh and it be good once thawed?
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