I have been sending out mugs for several years via my http://www.photomugs.co.uk site and I buy a stiff cardboard box from Direct Consumables at abot 25p each. I always wrap a mug with bubblewrap and get very few breakages.
Funny enough Xpress sent me a mug sample once in a polystyrene box, and guess what, it arrived broken! Don’t bother with Xpresses cardbord boxes they are not strong enough.
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