Labels,
Glad to help any way I can.. We're on a daily scheduled pick-up with FedEx, it costs CAD$6.00 per week. If you want, you can drop your parcels off at a depot or have delivery-on-demand (just calling their 1-800 number) and then there's no weekly fee (at least, I wasn't charged one). If your orders are < $200 in value, the parcels clear through customs using something called a Section 321 provision, which basically means no duty nor customs fees payable (though make sure you include the harmonized system code for your commodity on the invoice), and you don't need to provide any additional customer information. The annoying thing compared to the post office is printing off 5 copies of a commercial invoice or customs declaration (basically the same thing).
Now, if the value is over $200, it gets messy. Customs then wants you to provide the SSN or EIN number of your customer, and the fee for clearance is $16 USD. Ouch! With all the identity theft going on out there, not too many people are happy to share their SSN numbers (equivalent to our SIN #'s)!
What we do is either split our shipments over multiple days to ensure each shipment is below $200 in value, or you could always 'fudge' the invoice value (not that we do this or recommend it!)
The rates should be close to UPS's.. The delivery time is from 2 days to New York State (from Ontario) to 6-7 business days to California.. You can download FedEx Ground rates from the www.fedex.ca website.. Remember to add the residential and/or rural delivery surcharge to get a good idea of your maximum rate (UPS has these fees too).
We're getting some good discounts, but then we're shipping 400 to 800 40-pound boxes per month.. But even before our volumes got that high, we were getting at least 10% on all our shipments.. Call up FedEx and ask to speak to an account executive for your area, they'll be able to issue 5% discount on the spot, and higher discounts they can request from FedEx Ground's head office in Pittsburgh.
On the downside, FedEx Ground isn't quite as perfectly integrated as UPS Standard. This means you'll have a separate account number for Ground service, and a different account number for Express service, but it's not really a problem, since we ship 99.9% by Ground anyways..
Ourselves, we're looking into opening a US-based distribution warehouse - ultimately, that's the way to ensure the lowest rates and fastest delivery times.
Hope that helps!
-Tomasz