Just thinking out loud here and I wish I'd thought of this sooner.
I hang out on the Hero Games forums (the guys who do the Champions RPG). They've been doing order fulfillment out of their warehouse for a while now, and about six months ago they bought Indie Press Revolution. Can they get you a better deal than you have currently? I dunno but I think it's at least worth an email to find out. See the contact page on the http://www.indiepressrevolution.com website.
Also: Hero Games recently had some trouble with overseas printing as well. They might be willing to give you the name of the printer in Texas they found. Same prices as overseas but much better shipping times. (I don't know who they are using.)