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I have up to 50 figures each packed in 6x8" food containers(sorted by units). The food containers are packed 8 containers and loose items (siege equipment/landscape features) in larger under bed plastic storage bins(sorted by campaign). When I move the figures are going to bounce around in the open spaces in the food containers. Suggestions needed for padding material; I can buy a huge bag of styrafoam pellets which are sold to refill bean bag chairs or I could just shred a bunch of newspaper to use. Would the styrafoam be more abrasive? I also saw shredded foam for sale,but I have not been able to relocate the source.
Not as big a task as yours but when I moved some figures a few years ago, I layered them in layers of toilet paper. I did have the advantage that I was not having to pay for it and my collection was small. With a lid on the container holding the last sheet firmly but gently in place, there was no movement.
A wad of Polyfill stuffed in the plastic container works wonders to keep your painted figures safe. You can get it at most craft stores.