Picture 12 - "veteran" copier paper boxWhy can't there be a universal omnibox that can hold everything (especially horses), collapses when not in use, is lightweight, repels weather, is well self-padded, and costs next to nothing? I think the reason is the Japanese haven't found the profit margin in it yet. Darn. So we mortals are stuck with what is available.
As you look around your tiny abode, you note all those boxes collectors and vendors have been shipping you. Why can't you use those? Or you see stacks and stacks of copier paper boxes at work near the garbage bin; why not those? Go ahead and use 'em - if you don't travel much, are looking for an inexpensive alternative and don't expect rough handling or wet weather.
Picture 12 - "veteran" copier paper box
It's been on one airplane trip; it's been punched, bruised, crushed; no horses were damaged, but you can't always find a new box for every trip.
If you do choose cardboard as your container, remember that the larger the box, the less support on the sides; you may get some strength back if you choose heavier cardboard construction. Choose a "complete" box - no missing flaps. You may want to secure all seams and edges with some extra supportive tape (duct tape makes a good choice, but can be messy if you go into a hot area). If you have to purchase boxes, they range from free - at the grocery store or your company's receiving department - to $5 or so depending on the size and source of boxes. I got quotes from a packing store of $2.20 new and $1.90 used for a 3 cubic foot box; and a used 4.2 cubic feet box for $2.09. (Cubic foot = 1 foot x 1 foot x 1 foot) A 3 cubic foot box would be approximately 18" x 24" x 12". Purchasing from a packing materials store, you might be able to get a bundle of 25 boxes 16" x 14" x 8" (fits a traditional sized horse) for under $2 each or a 14" x 12" x 6" (classic scale) for around $1 each; varying the size slightly can significantly change the cost of a box. Don't forget all the storage space needed if purchasing larger quantities.
For shipping, cardboard is about the only way to go, especially if you are shipping something one way (to someone else). If used properly, they can be used, and reused... I had one box that I received from Chicago, that I shipped to Germany, that was returned, and then I shipped it to Michigan; maybe it'll return someday. Some shipping companies require new boxes if an item is insured; check with your shipper for any restrictions and recommendations.
For delicate models, you may want to consider double boxing (not a bad option for transit, either). This means you find a smaller box, at least 1/4 the size of the large box, and wrap the horse well and pad this inner box. You then pack the small box in the center of the larger box. Provide at least 2" of padding all the way around the inner box. This is how Hagen-Renaker ships its larger-than-mini horses (i.e., Jamboree, Encore) and Border Fine Arts ships its large resins (i.e., Champion of Champions). When shipping chinas, double boxing is highly recommended (but adds at least $5 to the materials cost for shipping, not to mention the added shipping charges due to the increased weight and/or dimensional shipping that may be imposed). Double boxing does not guarantee non-breakage, but does greatly improve the chances.
What other options are there for containers? Luggage for one. No, not the softsided kind (unless you carry them on), but the hardsided ones, and also trunks. Luggage has some inherit padding built in, and is very sturdy (remember the old commercials with the gorilla banging around the suitcase). It also has a built in handle, and often a lock. Additional padding is recommended. Luggage is reusable, but starts about $30 and goes up to $100 or more. Trunks, if large enough, can not only contain your horses but also your performance tack and props. Just remember to include sufficient padding all around. If traveling by air, ensure that your luggage meets regulations (including any size or weight restrictions). Some older trunks do not meet the standards. The weight of trunks can be heavy; a luggage cart or tipping a porter ($1-$5 per item every time it gets moved) are two options to move it. For hand carrying, softsided luggage is fine; you still should carefully wrap each piece you carry and provide some "box" padding around the inside.
With the improvement of technology, there are plastic containers, reasonably priced ($20 - $30) that are hardsided, tough containers with locking lids, that can be used for packing. Rubbermaid's Action Packers is one line that has a number of different sizes. The clasps that close the container generally have a set of holes to allow the use of padlocks to keep the contents secure. In my opinion, these are the best containers to use. They are extremely durable (strong enough to be used as a chair or even a step stool), and lightweight (when empty). The large box shown below is one inch in size smaller than the oversize baggage dimensions. The best time of year to find this size container is August/September due to "back to school" needs; other times of the year you might need to purchase via mail order.
Picture 13 - large Rubbermaid Action Packer
Another alternative is some form of customized containers. I have seen showers arrive with their horses separated in chest-high compartments lined with felt. These are fine for driving, but the head has no protection and the items cannot be transported by air or freight and are not protected from the elements. These might be nice as shelf holders. The containers are made of 1/4" plywood.
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