Shipping dunnage is the protective packaging or supporting material that secures and cushions cargo during storage or transit. It can take many forms, from bubble wrap and kraft paper to foam and even steel. By choosing the right type, third-party logistics (3PL) providers can reduce damage rates, cut replacement costs, and build a reputation that keeps clients coming back.
Read on to learn what dunnage is, when to use it, types of dunnage materials, and how reusable dunnage impacts sustainability. You’ll also see how warehouse management software like Logiwa can help you take control of your packing and shipping workflow.
What is dunnage?
In logistics, dunnage is any material used to protect cargo during storage or transit. The term is used in the rail and heavy freight industries, where it refers to materials like wood blocks that keep goods stable during travel. In shipping, however, it includes a broader range of materials, such as bubble wrap, kraft paper, foam, and steel.
Dunnage has three main functions: preventing cargo from shifting, absorbing vibrations and impacts that accumulate over long hauls, and creating moisture barriers for sensitive goods such as electronics or pharmaceuticals.
When to use dunnage
Dunnage is vital for many types of commercial shipments. As a general rule, 3PLs should use it for the following scenarios:
- Fragile or high-value items are involved: Products that can crack, deform, or shatter need dunnage that absorbs and distributes force before it reaches the item.
- Cargo is heavy or palletized: Large loads on flatbeds or in trailers need bracing to stay evenly distributed and prevent lateral movement when the vehicle makes a corner or brakes.
- Shipments are long-distance or multi-leg: Dunnage for long trips helps protect products from cumulative rough handling.
- Goods are prone to moisture damage: Humidity can compromise sensitive products like pharmaceuticals and electronics before anyone can spot visible damage. Dunnage can create a physical barrier that protects these goods from moisture.
9 types of dunnage materials
3PLs can choose from several types of shipping dunnage:
- Bubble wrap: One of the most common dunnage packaging types, bubble wrap is best for wrapping fragile items like electronics and glassware. It’s widely available and can be reused, although it’s not the most sustainable packaging option.
- Kraft paper: Made from recycled paper, kraft paper is slightly less protective than bubble wrap. At the same time, it’s one of the least expensive options, eco-friendly, and great at blocking moisture.
- Foam: Foam is one of the most secure dunnage options for irregularly shaped or fragile items. It’s commonly used for electronics, precision instruments, and medical devices, and is usually cut or molded to fit the product. On the flip side, it is comparatively costly, especially for smaller operations.
- Air pillows: These inflatable plastic pouches fill void space to keep items from shifting. They are lightweight and generate less waste by volume than loose-fill alternatives. On the downside, they can puncture easily.
- Packing peanuts: These loose-fill pellets conform to the shape of the content and absorb shock from multiple directions. Most are made from Styrofoam, which is not eco-friendly, but biodegradable cornstarch variants have become more popular.
- Corrugated inserts: These layered cardboard dividers separate items within a single carton to prevent contact between units. These are great options for bottled goods, glassware, and any products where item-to-item collision is the main damage risk. However, they provide limited cushioning against external impact on their own.
- Wood: A freight logistics staple, wood boards and panels are placed under pallets or between cargo tiers to distribute weight and create clearance for forklift access. It’s ideal for heavy industrial cargo. The downside is that international shipments using wood dunnage may need to meet ISPM 15 phytosanitary treatment standards, which can be expensive and time-consuming.
- Solid plastics and steel: Heavy or high-value loads, such as automotive components and machinery, need rigid structural dunnage like solid plastics and steel. While expensive, these options are effective, particularly at stopping heavy products from damaging lighter ones.
- Custom options: If you have fragile items as well as those with specific dimensions, you may want custom dunnage options. Custom dunnage providers can help design protective materials to your exact product dimensions. The tradeoff is cost and lead time, which makes it impractical for high-volume or time-sensitive operations.
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Reusable dunnage for sustainability
Single-use dunnage is convenient, but it adds up over time in packaging costs and waste, especially for high-volume operations. That’s why 3PLs should consider replacing single-use materials with reusable dunnage systems, such as steel racks, molded plastic trays, and fabric dividers. These dunnage types can significantly lower shipping costs over time and help you achieve your sustainability goals.
Reusable dunnage works best in closed-loop supply chains, where the same carriers and routes make return logistics practical. Automotive manufacturing and industrial freight are natural fits, since the same components move between the same facilities on predictable timelines.
Take control of your packing and shipping workflow with Logiwa
Picking the best dunnage for your goods doesn’t happen in isolation. It’s part of a broader pick and pack process that includes pack station setup, shipping label and packing slip generation, carrier integration, and shipping cost management.
If dunnage standards are inconsistent, products are more likely to be damaged, leading to damage claims, returns, and reputation loss. On the other hand, when 3PLs take the time to define and enforce dunnage standards, fulfillment outcomes are more likely to improve across the board.
To streamline packing and shipping operations at scale, consider adopting digital warehouse management software. Logiwa can help you standardize packing workflows, so dunnage system selection actually brings the desired results.
Curious to see how Logiwa IO works? Book a demo today.
FAQs on dunnage in shipping
What is the difference between dunnage and void fill?
- While these terms are often used interchangeably, void fill is actually a specific function within the broader category of dunnage.
- Void fill refers to materials—like air pillows and kraft paper—used specifically to fill empty space in shipped parcels so products do not move around inside the box during transit.
- Dunnage is the overarching term that includes void fill, but it also covers materials used for blocking and bracing heavy items, as well as cushioning to absorb shock during the sorting and delivery process.
How do dunnage bags work for freight, and how do I choose the right one?
- Dunnage bags are flexible, air-filled cushions placed in the voids between cargo to secure, stabilize, and protect goods during transit.
- When dynamic loads occur, the bags compress to absorb the shock, keeping pallets and break-bulk cargo safely in place.
- Selecting the right bag depends on the weight of the product, the size of the void, and the transportation mode.
- For example, over-the-road (OTR) truck shipments typically require Level 1 bags, whereas rail and sea shipments require more durable Level 2 through Level 5 bags to withstand rougher transport.
How does proper dunnage packaging impact eCommerce profit margins?
- Although protective packaging is an upfront expense, failing to use the right dunnage is ultimately far costlier for your bottom line.
- The right dunnage reduces product damages, which directly translates to fewer costly refunds and fewer inventory write-offs.
- It also lowers return rates by sparing customers the hassle of replacing broken items, which in turn strengthens long-term brand trust and repeat business.
What are the most common mistakes to avoid when using shipping dunnage?
- Overpacking: Stuffing boxes with excessive filler not only increases material costs but also frustrates customers during the unboxing experience.
- Incorrect Inflation: When using dunnage bags, overinflating them can cause the bags to burst or damage the surrounding products, while underinflating them fails to provide enough pressure to prevent cargo shift.
- Improper Placement: Placing dunnage bags where they touch trailer walls, floors, or pallets can cause friction-based wear during transit, leading to bag punctures and cargo damage.
