I can assure you, at least for me, shipping tropical plants and particularly orchids, has been an evolution for me. I package my orchid plants for shipping completely differently than I did three years ago. Originally, I simply copied what I thought was the best I had seen that other growers did. I take more time and care now, and yes, it costs me a bit more, but for me at least, knowing my plants will arrive in better condition makes it all worth while.
The one thing that should not be forgotten in all this is the abuse the boxes get while in transit. That is something that I cannot control. I have only asked the USPS to refund my money once, when one of my boxes was practically destroyed and I had to refund the buyer. I never got a cent from the USPS (which did not and does not surprise me!).