Hi Soapylove, My DD has been making soapsicles for 2 years now and she packages them in clear bags with a fold over easy peel and stick seal.
This bag is long enough and narrow enough for the entire pop, stick and all goes into the bag. The bag is more of a cellophane type plastic than regular type plastic.
I don't have any of her stuff here to show a pic.
She only makes about 300 per year so although they may smudge she does not ship any and this plastic seems ok to her.
I know she lays them in plastic bins in individual layers with thin sheets of flat styro board in between the layers, I think this is so the plastic does not get smudged?
I would think though for you and the amount you make and ship you really would need a time efficient packaging system. I would say DEFINATELY get the boxes.
So much of your time is spent making a lovely product and you don't want to see it all smudgey on the wrap.
Although it is a huge outlay of money to get the boxes, your product is worth it to protect it. It is always very difficult to justify spending money on packaging,
but packaging too can sell a product as well as protect it.
Of course they are just my humble opinions.

I do hope you find a solution.