Dunnage 101: Definition, Purpose, and Types

Shipping products safely requires more than just a sturdy box. Inside every well-packed shipment is a system designed to keep items secure during transit. One of the most important elements of that system is dunnage.

So, what is dunnage? Why does it matter in shipping? This blog will answer those questions, as well as discuss the most common types used in modern packaging and logistics.

Key Takeaways

• Dunnage is the protective material used inside packaging to secure and cushion products during shipping.
  
  
• Proper dunnage helps prevent items from moving, breaking, or becoming damaged during transit.
  
  
• Common types include loose fill, solid materials, and inflatable packaging, among others.
  
  
• Using the right material improves shipment safety, reduces returns, and enhances customer satisfaction.

What Is Dunnage

Dunnage is used in shipping containers, boxes, or pallets to protect and secure the cargo during transportation. Think of it as buffers between products and the outer packaging.

Your packages can experience different things while in transit, such as:

• vibrations
• drops
• stacking pressure
• sudden movements

The primary goal of dunnage is to minimize these risks. They help prevent movement, absorb shock, and reduce the risk of damage.

Many industries, including eCommerce, manufacturing, and retail, use it to make sure nothing goes wrong during transport.

Types of Dunnage Materials

Each type of packaging requires a different level of protection. Below are the most common dunnage options used in packaging and logistics:

Loose Fill

One of the most common dunnage materials is loose fill. It's a small, lightweight material used to fill empty spaces in a box. They prevent items from shifting and provide light cushioning.

Common examples include:

• packing peanuts
• shredded paper
• biodegradable foam fill

They work well for irregularly shaped items or for packing multiple products together.

Solid

From the name itself, solid dunnage materials are firm and structured. Most of the time, their function involves separating products, reinforcing packaging, or supporting heavier loads.

Examples include:

• cardboard inserts
• wooden blocks
• mould pulp trays
• plastic dividers

You will often find these materials in palletized shipments or fragile items that need individual compartments.

Inflatable

The inflatable ones use air-filled packaging to stabilize items inside the containers or boxes. They expand to fill space, preventing movement during transit.

Examples include:

• air pillows
• inflatable dunnage bags

This type of dunnage is lightweight and efficient, adding minimal weight to shipments while still providing strong cushioning and support.

Cushioning

Like solid dunnage, cushioning (or foam dunnage) also absorbs shock and impact during shipping. These materials help protect fragile or delicate items from drops, vibrations, or pressure.

Common cushioning materials include:

• foam inserts
• bubble wrap
• padded paper

You can find these types mainly on electronics, glassware, cosmetics, and other breakable goods.

Protective

Protective dunnage focuses on shielding products from scratches, moisture, or surface damage.

Examples include:

• stretch wrap
• foam sheets
• kraft paper
• plastic film

These materials are especially useful when shipping items with delicate finishes, polished surfaces, or sensitive coatings.

Void Fill

Void fill is a material used to protect items and to fill the space inside a package. Like inflatables, void fills act as stoppers to keep the items from moving around during transit.

Examples include:

• crumpled Kraft paper
• air pillows
• packing paper
• foam inserts

Proper void fill helps maintain product positioning and reduces the risk of damage.

Note that you can also create custom dunnage applicable to the type of products you're shipping.

To make it easier to compare your options, here’s a quick overview of the most common types of dunnage mentioned above.

This table highlights what each type is most ideal for, along with typical examples, so you can quickly choose the right materials based on your packaging needs.

Benefits of Using Dunnage

Using the right dunnage for shipping offers several advantages for businesses that regularly deliver products. Here are some of the benefits you should know:

Protects Cargo from Damage

They become your product's protective barrier that absorbs shocks and impacts. It reduces the likelihood of items breaking or becoming damaged while travelling through the shipping network.

Prevents Movement and Shifting

Constant movement while in transit can cause various issues with your item. Therefore, it is crucial to place the protectors inside your package properly. They don't just place the items firmly inside the package. Dunnage prevents items from sliding, colliding, or shifting during transport.

Improves Load Stability

For palletized or bulk packages, it helps distribute weight evenly and maintain load balance. As a result, it improves overall stability during loading, stacking, and transportation.

Reduces Returns and Losses

Damage during shipping and handling often results in product returns, refunds, and replacement orders. Dunnage may help you protect products as they're on their way to your customers, reducing costly and stressful issues.

Enhances Customer Satisfaction

All customers expect their orders to arrive in perfect condition. Well-packed items that use effective dunnage not only prevent damage to your products but also contribute to positive customer experiences and stronger brand trust.

Optimizes Packing Efficiency

Using appropriate dunnage allows businesses to pack products more securely without overusing packaging materials. It helps maintain efficient packing workflows while still protecting shipments.

Supports Compliance with Shipping Regulations

Certain products require secure packaging to meet carrier and regulatory guidelines. Dunnage helps ensure shipments meet these requirements by stabilizing goods and preventing hazardous movement.

Final Thoughts

In conclusion, dunnage plays a critical role in modern shipping and logistics. Learning about the different types of dunnage and how they work allows businesses to be flexible. They can choose the packing materials that best suit their products.

The right strategy protects products, improves operational efficiency, and enhances customer satisfaction.

Prioritize Shipping Safety: Explore Dunnage Solutions with Stallion

With Stallion, our 3PL services are more than just streamlining your shipping processes. We ensure your packages are well-packed and protected for transit.

• Are your items for domestic deliveries?
• Do you ship across the border?
• How about international shipments?

We help simplify logistics and reduce shipping risks, and no longer have to worry about these issues.

Stallion handles these tasks for you!

Start optimizing your shipping workflow today and explore how the right packing practices can keep your products safe from warehouse to doorstep.

Jose Sagun

Jose is Stallion's Senior Business Analyst. He helps improve the company’s shipping processes, works closely with delivery partners, and looks at shipping data to find the best prices for our customers. Outside of work, Jose has a passion for running, regularly completing 5k and 10k runs, with the goal of running a full marathon in the near future.