Vic, a thought there might be to use a single 11" x 17" sheet of paper folded around the outside of a hardcover. Costing obviously is your department but spreading the price of a ream of paper over 500 shipments, plus the few seconds to wrap the book may or may not be affordable.
Sharp, professional observation about the possibility of scuffing too, nice insight into the thought process. I'm currently applying for a job in packaging, this helps me get into the mindset, I mean! :-)