We had a customer order 240 sweatshirts for her husband in Afghanistan. We packaged them in 4 25 x 13 x 8 boxes with the corners solidified and taped above average. When filling out our customs information we were told that it was a good idea to also include a copy of the shipping label as well as customs information inside the box as well as outside, to make it slightly less likely to get lost if it was opened for inspection.
That is unforunate though that the packages aren't making it intact. Shipping UPS or Fed Ex isn't going to be a significant improvement to USPS, as USPS would make the delivery either way. It'll just be directly through USPS, or you'll choose FedEx who will then subcontract the package to USPS.
I do think the bubblewrap idea is a good one. It's not all that expensive, and does let things arrive in better condition. I really don't know what to say about the stealing and vandalizing though.
That certainly is a ***** development. I know for a fact USPS won't do anything about that. At least with a FedEx shipment you may get some sort of insurance refund (after fighting with them for about a month).
My husband (and siblings) have been deployed more than I can count. Not once were their package eaten by a rat or lost. You have bad luck.
Sorry to hear he isn't getting the packages. Ship with USPS; use flat rat boxes. Tape the hell out of it to seal and pack tightly and safely; I remember every inch of the boxes I sent were taped because of the chances of seals breaking open on transport.
Make sure you have the APO visible on a clear label with a proper customs form. Also, make sure your return address is also visible and is not just on the customs form. Here is a link for the APO flat rate boxes.
You can order for free online and the USPS will deliver them to your house. Https://shop.usps.com/webapp/wcs/stores/...
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