To keep it under 12 oz, you really don't have a lot of options.  If it was less than a dozen mailings, I'd just tape the modules between two pieces of cardboard and place it inside a legal envelope.  But with that quantity, I'd probably go with stay-flat mailers.  Something like this:

http://www.uline.com/Product/Detail/S-5 ... ay-Flats-3

Good luck!  

Zach
I will send you a link to a flat box supplier. They are reasonable and it keeps the weight down while keeping module safe. I started using these boxes a couple years ago and they seem to work very well. Getting on a plane and I have I to get out my laptop so when I get a chance later today I will shoot it over.

Bill

If you are not shipping in a box then I'd recommend the piece of cardboard as protection for the module.(one without creases, bigger than the module to protect all four corners and thick enough not to be easily bent. Creases in as cardboard backer are simply bend lines for the shipper and they will most likely bend your package, cardboard sheets smaller than the module act as crease lines during shipping and allow easy corner dings, and too thin cardboard is useless).

If you use an envelope make sure to write both Fragile and Please! Do Not Bend! on both sides of the package as large as you can. Write this on all your envelopes before starting the packaging process and it will save you time.

If you are using a sheet of cardboard from protection make sure to precut all the sheets that you will need beforehand. Tape your module to the cardboard to make sure the corners are securely within the cardboard sheet. (I used the priority mailers and found a single piece of cardboard worked nicely).

Bag your modules. Magazine size bags were running about $12-$13 per hundred.

bbarsh wrote in Shipping Modules Best Practices:http://www.papermart.com/easy-fold-vari ... =1169#1169

Here you go.

How much does one of these boxes that ship an 8 1/2 by 11 inch module weigh?  What I am wondering is whether this plus his 8 1/2 oz product are going to be light enough to ship First Class.  Hmmmm.....  

Yeah, he's in a real pickle because he can't ship Media Mail since there is a mini included, but if he goes over 13 oz, he just went from a little over $3.00 a package to about $5.00 a package, which is roughly a $200.00 shipping increase on those hundred packages.  But if items get damaged, he loses customer satisfaction and has to re-ship modules/minis to replace those that were severely damaged.  Too many dis-satisfied customers means lost future business.  If it were me, I'd take the ship-once-and-done option.  Zach, good luck!