I ordered a couple of 5x7 prints from a recent Star Wars Weekend visit and was surprised at the poor quality of the resulting prints. The color was washed out and there were stripes on both prints. For $13 a print I don't think its unreasonable to expect a minimum of quality control. Its obvious that these prints weren't even glanced at or they wouldn't have been sent out.
I opened a customer service case via the PhotoPass website and got an equally surprising response. They did offer to reprint the photos if the images were still available or refund them otherwise which is great, but required that the original prints be returned at my expense. I get that Disney is probably trying to avoid people getting themselves free double prints by needlessly complaining but I hate it when a business assumes I'm trying to cheat them and expects me to shoulder any expenses to correct their mistake.
In the end I called customer service, explained my problem with the quality, and the rep cheerfully offered to reprint them and expedite shipping of the replacements with no need for me to send in the bad prints (which are going straight in the trash as soon as the replacements arrive). So call if you have any problems. I didn't even have to ask for replacements, they apologized and immediately offered them.
Something else to be aware of. You aren't dealing with Disney when you . Like many services, Disney has contracted out production of the photopass products to at least 2 companies. Jostens (yes the class ring people) produces the photobooks in Kansas. Ezprints of Norcross, GA produces the prints and other products. Not sure who does the photo CDs but it would make sense for ezprints to do this as well.
This coupled with bait-and-switch type complaints I've been reading about pricing of photopass CDs makes me think Disney should take a bit more control of PhotoPass from the companies they've contracted to produce these products for them. Disney is known for high prices but good customer service and PhotoPass is gaining a reputation for having only half that formula.