I have never shipped film, but i work at a U.S. Customs Broker company and know a lot about U.S. Customs Procedures,
U.S. Customs Officers have Loads of work and will take any shortcut available, its easier to dump your package on the conveyor of an X-Ray Machine than to manually inspect it. By Policy U.S. Customs is supposed to concede to any WRITEN request to manually inspect exposed film, but often times they see the papers after X-Rays, so efective comunication with the U.S. Port of Entry is Essencial.
My advise is Generate a Customs Entry and contact the MET Department at the port of entry with your entry number and remind them of your request.
Exposed Film does not pay any duties, but there could be a few User Fees if the Declared Value is over $2,000 USD, but should not exced $100 USD Unles your shipping enough film to circle the earth.
You have 2 Options for an Entry depending on the Unexposed Value of the Film.
If the value of the Unexposed film you are shipping is less than $2,000 USD you can fill a form CF-7523 by yourself at http://www.cbp.gov/xp/cgov/toolbox/forms/
Tape a Copy of the filled form to the package
and fax a copy to the MET and ACS department of the Port of Entry, along with a writen request that the film be manually inspected in a light tight enviorment and not be exposed to X-Ray.
Istructions on filling form CF-7523
BOX 1. You can imput any reference number (Entry Number)
BOX 2. You can guet the Port Code an Phone number at: http://www.cbp.gov/xp/cgov/toolbox/contacts/ports/
BOX 3. Shipping Date
BOX 4. Shipping Company's Name
BOX 5. Estimated Arrival Date. (Acurracy not necesary)
BOX 6. Self Axplainatory.
BOX 7. Number of Packages.
BOX 8. Item Description and Oficial Unit of Mesure (Film is Square Meters=Linear Meters of Film * Film Format / 1000) "Exposed Film X M2
BOX 9. UnExposed Value of the Film in USD
BOX 10. the HTSUS No. for exposed Film is 3704.00.0000
BOX 11. Name and Address of Someone in the US (Could be yorself if you have a US Address)
BOX 12. Signature of Person on BOX 11 or a representative
BOX 13. Leave Blank
BOX 14. Name and address of Consignee (may be Same or different than BOX 11, Maybe a Lab)
BOX 15 & 16. Leave Blank
BOX 17. Same as Box 4
BOX 18. Signature from someone from Shipping Company.
In the lefover space on boxes 7 to 10 write in thik bolg big letters:
"DO NOT X-RAY"
"SENSITIVE MATERIAL"
"PLEASE INSPECT MANUALY IN A"
"LIGHT PROOF ENVIORMENT"
If the value of your shipment is over $2,000 USD. you'd better get a Customs Broker at the port of entry. you can guet a list of Licensed US Customs Brokers active in the port ate the port information page at : http://www.cbp.gov/xp/cgov/toolbox/contacts/ports/
Remember Customs Officers are Beureocratic creatures (you need a lot af patience and explain yourself several times) but they are also human and they respond better to a nice and polite request than to an aggresive or nagging demand.
Don't get to technical on them, often times they don't know what you are talking about.
I hope this information is useful to you all