I ship ties rolled up, wrapped in a piece of tissue type paper, inside a 4x4x4 box from ULINE. There is a 4x4x3 box available but I use the larger one because it will fit two ties if necessary. Of course these boxes can be nested to make a 4x4x8 if needed. IIRC the boxes cost between 30 and 40 cents each. I am not comfortable folding ties because of the possibility that they could be under a pile of stuff somewhere in the shipping process and could be creased.
I ship mine rolled too, for the same reasons.
How do you get them so cheap through ULINE? Their per box price usually seems decent, but then the shipping cost blows that up. My supplier has them for about $0.50 each.