I enjoyed your review, Gord Lacey.
I suppose it isn't the cardboard doing the scratching (it's cardboard, the sleeves can't scratch the discs on their own) but when transporting the set they come loose and slide around everywhere. It's like they got lost along the way in design of the set. It just doesn't seem very cost effective. I like the binder, but it turned out a little clumsy. There's not enough variety in the photographs and absolutely no Fraggles on the cover of the binder itself. The box and acetate covering (that should have been a slip-sleeve) just seem so weird. I purchased the set in a store, but have not played them all. The packaging, menus and the nature of this release holding fans hostage is just very unFraggle-like. If Hit had scaled down the creativity and released slim cases as you have stated it would have made more sense and possibly contained more Fraggley graphics. That's what fans want - character imagery, not some day-glow, fake rock binder that serves more to injure the material than protect it.
I still like my set and the binder, but I feel this is what happens when a company tries too hard to impress rather than simply being considerate to the fans.