How do I ship a single product in more then one box?
The solution is to set up Multiple shipping boxes for a product. This located by navigating to Catalog>Manage Products, select the product you want and then select the Multiple Shipping boxes tab. The screen shot below demonstrates an example set-up.
Then when the product is placed in the cart it will always ship in multiple boxes.
The following log shows that the single product is sent in three boxes.
Please bare in mind if you place multiple products in the cart then each individual product will be shipped in three boxes i.e two products placed in the cart will ship a total of six boxes.