All BS, of course. Most such people are charged because Customs open a percentage of all packages entering the country and have a look inside. And it's not necessarily at random; the method for reliably fooling a good sniffer dog has yet to be devised.
Until someone solves the problem that you can't easily do dual key encryption on molecules, people are going to keep getting busted by old fashioned customs and police work.
If he made a mistake, it wasn't some Tor-related misconfiguration. It's that he didn't bribe the right Customs officials.