Just interested how do you keep track of private/public key pair? Does the paper circles have public key on one side, private on another?
I use a database that tracks the funding status and denominations of the coins.
One simple script queues the coins for activation using a firstbits lookup. The database knows what addresses I have generated, and can auto reject typos.
Another script produces a "sendmany" script for bitcoind to actually send the BTC out (I paste it into a shell window). Using sendmany allows for bulk funding of coins in a single transaction, cutting out complexity and transaction fees. The full bitcoin address is pulled from the database so I never have to type any more than the firstbits.
Another script sets aside a batch of coins for later funding. This is used for international orders. When the orders arrive, I simply throw their coins into the activation queue.