I don't use the corrugated adhesive mailers or the Cro-nel ones either, though they might be good for someone who mails out a lot of chips all the time, as they are time-saving. I also have seen the chip inlays adhering to the adhesive.

This is the least expensive method for mailing inexpensive sturdy chips. I wrap them in paper (chips end to end; see picture), and then tape the paper bundle to a sheet of paper so they won't slide about in the envelope. The end product -- these three James Bond chips (which I'd sell for $6 postpaid, by the way) end up weighing just 2 ounces (chips, paper, tape and envelope), and the filled envelopes are no more than 1/4" thick! Thus, I can use first class LETTER rates. A two ounce letter costs 58-cents in postage. Since it is unmachinable (I guess, due to the unevenness and rigid chips inside), you add a 17-cent surcharge, bringing the total to 75-cents. Sent first class PARCEL rate in a bubble mailer, it would come to $1.30 for for 2 ounces (no surcharge issue there), or more likely $1.47 for 3 ounces., plus you have the cost of the corrugated adhesive paper. (I don't think a bubble mailer package would be accepted at first class FLAT rates because flats (a/k/a large envelopes) must be flexible and of uniform thickness.)

Robert