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"I have been consistently impressed by their ability to handle our complex needs and willingness to say yes to any challenge. Most importantly, I believe in the character and work ethic of the team."
Mike, Co-Founder & CEO
Millions of packages arrive at their destinations daily, but not many people ever consider what keeps fragile items intact during shipping. Learning the meaning of “dunnage” becomes crucial when you realize that protective materials directly contribute to business success and customer satisfaction. With shipping damage responsible for 20% of all product returns, the stakes for successful cargo protection continue to rise across industries. Most shippers today invest in quality protective products to safeguard both their products and the profit margin. This guide contains everything you need to know about dunnage in shipping, including its various types and uses, and its importance for effective logistics management.
Dunnage in shipping refers to protective materials that prevent goods from being damaged during transit. These materials are used to fill empty spaces inside and between packages, cushioning the contents of boxes during transportation. To understand dunnage, consider what is involved in shipping a fragile item, such as a ceramic bowl. Ceramics are usually wrapped with soft or bulky padding to prevent them from shifting inside the packaging. Heavy items like books, on the other hand, normally need very little protection since they can withstand typical shipping conditions. Using the right amount of dunnage with suitable packaging ensures that your products arrive in the same condition as they were when they started their journey.
Once you understand the purpose of dunnage, it’s not hard to figure out why shipping companies depend on these materials. Without proper dunnage, even otherwise perfectly packed cargo will arrive damaged and lose its value. Here are three reasons why dunnage has become indispensable for reliable shipping.
Shipping involves constant movement, vibration, and impact that can destroy cargo instantly. Dunnage creates multiple layers of protection around products, absorbing shocks before they reach your merchandise. Airbags provide excellent shock absorption by inflating between the load and the container walls during sudden stops or rough handling. Additionally, corner protectors prevent boxes from being crushed under pressure, and foam inserts cushion delicate electronics and breakables. Protection is not limited to physical damage, since moisture barriers protect sensitive materials from humidity and temperature changes.
Empty spaces in shipping containers become dangerous zones where cargo can slide around and collide. Dunnage fills these spaces completely, creating a secure room where nothing moves out of place. Wooden blocks distribute weight evenly across the container floors so that heavy weights don’t concentrate pressure in any particular spots. As a result, heavy furniture and machinery stay exactly where they were first positioned throughout the entire shipping process.
Correct dunnage use delivers high financial returns through better cargo protection and operational efficiency. Companies avoid the expense of product replacements, customer refunds, and time-consuming return processes when shipments arrive undamaged. Insurance costs decrease when businesses demonstrate a consistent record of safe deliveries. Workers can also handle properly secured loads more quickly and safely, reducing labor expenses and injuries. The upfront investment in quality dunnage materials typically returns ten times its cost through these combined savings.
Shipping companies use various protective materials to keep products safe during transportation. Choosing the right materials depends on how heavy, valuable, or fragile your products are. Below are the main types of dunnage that are often used to protect shipments.
Wood provides strong support systems for heavy loads like machinery and big appliances. Shipping teams build wooden crates and frames that hold these goods throughout the journey. The solid wood structure also makes it easy for workers to move packages around with forklifts and other lifting equipment. Wood pallets provide a stable platform underneath heavy items, making them easier to load onto trucks and ships. Because wooden protection systems are reusable, they help businesses save money.
Dunnage bags or air pillows are airbags that create protective cushions in shipping containers. When inflated, they fill gaps and stop products from moving during transit. The bags also automatically adjust their capacity to fit different container sizes and cargo shapes. Many companies use inflatable dunnage along with other materials like foam and bubble wrap for better protection.
Paper materials offer effective protection for lighter products while being environmentally friendly. The best paper dunnage options include the following materials.
Foam’s ability to conform to various shapes creates a custom fit around delicate goods, protecting them during transportation. This material is best for electronics and medical equipment that need careful handling. Foam absorbs impacts from all directions while keeping products perfectly still in transit. Different types of foam offer varying levels of protection, ranging from soft cushioning to firm support. Foam inserts for products of the same size and shape can also often be reused.
Steel frameworks provide the strongest possible protection for extremely valuable or heavy cargo. These metal structures distribute weight evenly and create rigid barriers that prevent product movement completely. Steel works best for medical machines, large electronics, and industrial equipment. The high cost of steel means it’s usually reserved for valuable goods, since damaging them is more costly.
Some products need protection that commonly used materials cannot provide effectively. Custom dunnage solutions often combine various materials, such as padding with rigid plastic or metal frames. Companies that ship medical equipment or valuable works of art often invest in custom protection systems. While these solutions have a high initial cost, they prevent damage to highly valuable or irreplaceable items.
Shipping products safely is not as straightforward as just putting them into boxes. Dunnage is your best bet when you need extra protection that goes beyond regular packaging methods. Below are some circumstances in which dunnage is used.
Choosing the appropriate dunnage material protects your shipments and spares you the cost of damage. Below are some considerations to keep in mind when selecting dunnage.
Product categories influence which protective method is best for safe delivery. If you’re shipping clothes, packing paper protects against fabric wrinkling, while poly mailers provide light protection against dirt and moisture. Electronic items are protected by anti-static foam to prevent electrical damage while handling and shipping.
Different transportation modes present their own challenges affecting the selection of dunnage. Ground transport involves constant road vibration, so shock-absorbent materials like bubble wrap work well to cushion the cargo. Air transit entails weight limitations, making lightweight materials, such as inflatable airbags, more practical than heavy wooden supports. Shipping by water exposes cargo to humidity and makes waterproof barriers essential for moisture-sensitive products.
The cargo’s weight will directly affect the amount of support your packaging will need to provide and the associated type of dunnage. Lightweight items, such as books and small electronics, require basic foam padding since they don’t exert much pressure on the container walls. Heavy objects, such as tools or metal objects, require wooden crates and added support that distribute the weight evenly on the bottom.
Some packaging materials are reusable, while others break down after one use. Plastic containers remain intact through repeated handling, and they’re a cost-effective option for many shippers. Metal frames can withstand harsh handling and continue protecting goods even after extensive use. These durable options also save money on waste disposal compared to single-use alternatives that end up in landfills.
Budget constraints determine which protection solutions are cost-effective for your business. Basic materials, such as corrugated boxes with paper padding, are inexpensive but provide adequate protection for standard items. Premium options like custom foam offer superior protection but are also more expensive.
Proper packaging is the secret to successful product delivery and customer satisfaction. When products arrive damaged, businesses must handle returns and refunds, and reassure disappointed customers who may be hesitant to order again. Encore Fulfillment offers reliable packing services using high-quality dunnage materials, including bubble wrap, kraft paper, and crinkle paper to protect your products during shipping. Our experienced packers follow careful protocols and use UPC scanning to ensure accuracy and select appropriately sized boxes, helping to keep your shipping costs down. Request a free estimate today!
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