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I have seen the same thing happen. That thick card stock is not good on round bottles.

Customs bond is $259/year, glass bottles are duty free under hts 7010.90.5019 .

Yes, we make custom molds for $10K with MOQ's of 5,000. No strings attached. Mexico is covered by NAFTA, so there are no duties to worry about, just freight. We currently have multiple projects in Hawaii. I bet I even have some freight estimates I can find. At 5,000 run quantities we are in the mid $2 range depending upon design. Do you label during fill, or should we also look at artwork and quote decoration? Once we have the design and can create a packaging specification, then pallet configuration, we can figure out how to optimize the container. A 750ml in a 12 pack reshipper would be about 15,000 in a full 40 foot shipping container, so 5,000 means we might want to look at a 20 foot container rate, plus upping the order size a bit to max out the 20 foot. Very close to our factory is also the Stopper supplier, TAPI. Maybe we can consolidate with them to save costs too. I am sure they can bring their corks to us before we seal the container. I am a firm believer in sealed containers door to door. When is a good time to speak? Brooke 860-350-5485