We deal with a variety of parcels everyday at The UPS Store so we`re used to advising customers on proper packing techniques. This is a photo of one customer who chose not to take my advice and ship here package how she wanted to.
She is a hockey players wife who bought several large boxes to pack some household goods. She was bragging about how much she was able to fit into each box. I cautioned here that the boxes she was using despite being large were not designed to hold 150 lbs and they likely would be damaged. She assured me they were well packed and would be fine. Sure, like I have no idea what I`m talking about. "Ok, you can ship them if you want to but they`re probably going to get damaged."
Predictably, I received a phone call two weeks later and she was crying about how rotten UPS must be to do THAT to her boxes. She even sent photos so I could see the extent of the damage. Sure enough, some of the boxes had been literally destroyed. She was lucky the contents even arrived as some of the boxes were being held together by multiple layers of stretch wrap.
Anyway, the moral of the story is...Never put 150 pounds of stuff into a box that was only made to hold 65 lbs, or as I like to put it "Pack for the worst then pray for the best."
I know I`m very late to chime in on this, but I`ve been out of touch for awhile. First of all, have you found any good solutions to your challenges? You mentioned 1) difficulty in finding appropriate size boxes, 2) selecting proper internal packing material and 3) finding a freight shipper who won`t destroy your merchandise. I may have some suggestions for you if you are still looking for solutions. Let me know where you`re at right now and I`ll go from there. Thanks,