Are there any companies that do what you do?  When we were looking into packaging & shippers we looked at what our competition uses.  And I can tell you we tried to cut corners on shippers and it piad off with re-shipments and damaged orders and finally we realized that it is much cheaper to pay up front to ensure your product arrives in good condition. 

As for packaging all I can tell you is I have learned a lot since I first had packaging done.  Pay attention to packaging!!  It is amazing what ideas you can get from others. 

Good luck and as hard as it is to not do it don't skimp!