The priority mail boxes have a lack of rigidity because they are thinner than the average cardboard box. When you have a chance, look at an Amazon box vs a USPS flat rate one. No matter what service you use, no one is going to be particularly gentle with your package. Cliff has mentioned that he stopped labeling fragile on his pawpaw boxes to friends cause it seems they always arrive with more damage not less.
As you know, pawpaws get easily bruised, more so if shipped, since the box has to go through conveyer belts and deal with handlers throwing packages onto the back of shipping vans. Most of the produce that comes from HelloFresh don’t bruise easily. If you don’t use an internal box, spray foam is still a bad idea since it hardens. The pawpaws need material that has give. Anything solid is a bad idea. Also, the longer the duration of shipping the more insulation you need obviously to prevent heat transfer. At the same time, the more insulation you have, the more ethylene build up you have to compete with once the entropy increases (cold packs no longer cold).
HelloFresh is a poor example to look at (imo). Almost anything that HelloFresh ships I basically can drop on the floor or throw against a wall and comeback a day later and still use. You can’t do that with a tree ripe pawpaw. Also how cold is the cold pack when it arrives? Not very cold. That’s part of the problem. You may help the pawpaw’s condition for the first 18-20 hours, but you also create conditions to accelerate ripening after the cold pack is no longer cold.
Location also matters [for cost], I’m almost at the transit hub conveniently to ship things to either coast for the same cost. HelloFresh has more than one distribution center to make transit shorter (and cheaper). I can ship to Washington at the same cost as I can to Virginia (roughly speaking). Other’s don’t necessarily have this benefit. Someone else in North Carolina, for example, may find they have no choice but to pack less pawpaws with more freezer packs to mail to someone in Oregon because their overnight shipping costs would be 30-40% more than mine.
I do agree that there may be other people wherein it makes more sense to try with more insulation due to their location dictating higher shipping costs. That’s not the case for me specifically. It simply makes more sense to pack more pawpaws in and go with a faster shipping method. I’m not shipping to a cliente though and I pass on actual shipping cost to everyone on this forum that asks because I’m not operating a business. Integration Acres, Earthly, and others have to pay wages so there’s not just the shipping fee, handling costs and the cost of the actual pawpaws.
Though, I would point out, newspaper is free (for me at least), cold packs, foam spray, cooler box, ethylene absorbers are not. There’s going to be a break even point where overnight is cheaper. Too many variables for me to worry about extending shipping time. I’m not in a business so its just easier to require overnight shipping.
If there’s one major fault, I tend to completely overthink things and get into tons of minutia. (This post is a good example.)
Ask @Barkslip next time how I nearly drove him insane with all my hot pipe callus questions. “Just graft the damn thing. Stop thinking so much” or something along those lines, I think was one of his messages. My emails with @scottfsmith, @SMC_zone6, and Andy Mariani about peaches get pretty nitty gritty (sometimes about genetics) too because I have very specific targets for peaches that I grow.