I know what you mean about those big ol' boxes. Heck, I've also heard a lot of praise about them, and can see why GR continue to use them (furthering the whole "quality product" mindset), but let's be honest; you could get the Dragon Age GM kit into a large envelope. I would really appreciate an option to have that; just a little checkbox on the order screen, so that you can continue to be trying to provide a quality service, despite your penny-pinching players.
I say this mainly because I know that no matter how well packaged a gaming aid is, it will be covered in salsa and crumbs within five minutes of removing it from the box anway, and so the saftey of my cardboard during shipping isn't of paramount priority to me.
On the other hand, I can see how something like this could cause a lot of micromanagment issues, which would just up the handling cost as muchas it would lower the shipping costs, so I guess it's up to someone at GRHQ with a calculator and some pateince for numbers.
As an aside; ouch on the currency there...