What is the shop or customer experiencing? The shop reported an issue with shipping label costs. They are being charged different amounts for the same customer with a similar package weight. Additionally, despite selecting 'Poly Mailer' every time, the system is consistently charging them the rate for a 'Box'.

What is the expected behavior? The shop is using CS Shipping (Flexlabels disabled). Although pricing should be calculated strictly based on the weight class, the system is intermittently applying a higher "box" rate to orders of a similar weight where "Poly Mailer" was selected.

What error messages are there? The shop also reported experiencing an error while trying to print the shipping labels. Unfortunately, they were unable to capture a screenshot before moving on.

Did you replicate? NA

What settings were checked? Confirmed the shop is using CS Shipping (without Flexlabels). Reviewing the logs, orders of nearly identical weights are generating different shipping label costs.

Provide examples, sku, order #, customer names, and screenshots where possible. Order Nos: 856, 853, 848, 855