“Dunnage” is not a typical word that the average consumer would know, but it is, however, a common term for shippers. Dunnage is the word used to describe packaging components like crinkle paper, blocks, boards, fillers, bubble wrap, plastic bracing and more. Dunnage protects goods during shipping and handling, prevents movement, and cushions items from impacts or vibrations.
In e-commerce fulfilment, dunnage acts as the unsung hero that protects products from the rough conditions of transit. Without it, even the most secure packaging might fail to prevent dents, cracks, or scratches.
We’ll explain the importance of dunnage, its benefits, the different types, how it’s used, and the best practices for using it.
The Importance of Dunnage in E-commerce Fulfilment
Without dunnages, you can expect inefficient supply chains, unsatisfied customers, too many returns, and damaged products ending up in landfills. Dunnage is not just important for your business or for a fulfilment centre’s operation, it’s important to your customers.
Dunnage can:
- Get rid of void space. It fills in the gaps between items so the product doesn’t slide, slip, or get jumbled around as it’s shipped across land, sea, or sky. It also protects products against rough handling.
- Absorb shock. Fragile items are prone to shattering and breaking if they’re handled harshly or moved around too much during transit. Air pillows and bubble wraps are examples of dunnages that absorb much of the impact that occurs during transit and protects fragile goods from damage.
- Protect against dampness. Sometimes, because of certain environmental conditions like rain or humidity, parcels can get a little damp. This can cause issues for electrical items, food, and books.
- Improve customer satisfaction. Needless to say, customers won’t be happy to receive damaged items. They will be even more unhappy if they notice that their parcel wasn’t packed in a safe or protective way. Not only will you end up footing the bill for replacement and shipping, your customers will less likely buy you from you again.
The Benefits of Dunnage
Dunnage plays an important role in order fulfilment. There are numerous advantages that contribute to fulfilment centres’ operations. What advantages does dunnage bring?
- It reduces damage and returns. Dunnage minimises product movement and lowers the risk of damage during storage or transit. Fewer damaged goods lead to fewer returns. It saves time, money, and resources.
- It helps your business save money. It prevents the need for costly product replacements and repairs, and can also reduce additional shipping fees and customer service workload associated with handling complaints or returns.
- It improves packing efficiency. Dunnage streamlines the packing process by providing standardised materials and easy-to-use solutions. It simplifies handling, increases potential labour cost savings, and organisation in warehouses to make processes smoother and faster.
- It improves customer experience. Well-protected products arrive in perfect condition. It minimises customer frustration, creates a positive impression, and increases repeat business.
- It supports sustainability goals. Eco-friendly dunnage materials, such as recycled cardboard or biodegradable air pillows, minimise environmental impact. It reduces waste through reusable or recyclable packaging options.
Types of Dunnage Material Used in the Order Fulfilment Process
The right type of dunnage protects products and optimises the order fulfilment process. Different dunnage materials serve specific purposes based on the weight, size, and fragility of the items being shipped. Below are the most common types of dunnage used in e-commerce fulfilment and their applications:
1. Paper Dunnage
Dunnage paper is lightweight, cost-effective, and fills voids in shipping boxes. It cushions products by crumpling or folding to absorb impacts and prevent movement. It’s also eco-friendly and great for businesses who want to reduce plastic use.
It’s biodegradable and recyclable, affordable and versatile, and suitable for lightweight and medium-sized items. It’s usually best for books, apparel, and non-fragile goods that need light protection during shipping.
2. Air Pillows and Bubble Wrap
Air pillows and bubble wrap serve as a lightweight barrier of air that shields fragile products from shocks and vibrations. Air pillows are excellent for filling large gaps, while bubble wrap offers direct cushioning around delicate items.
It’s lightweight, reduces shipping costs, effective for fragile or breakable items, and reusable for added cost efficiency
This type of dunnage material is commonly used for electronics, glassware, and cosmetics that require impact protection.
3. Foam Inserts
Foam dunnage is custom-moulded to fit around specific products. It’s used to pad electronics, medical devices, automotive parts, and fragile or sharp instruments. It ensures maximum security during transit.
Foam is often used for high-value or sensitive equipment that cannot afford to shift within packaging; they’re customisable for exact product dimensions and have excellent shock absorption.
4. Wooden Dunnage
Wood dunnage is used for shipping heavy, large, or industrial items that need strong support. Dunnage boards help stabilise loads and prevent damage during long-haul shipping or international transport.
It’s durable and robust, handles heavy weights, and reusable for multiple shipments. They are ideal for machinery, large equipment, and furniture.
5. Corrugated Cardboard
Corrugated cardboard serves as both a box material and an internal dunnage solution. It can be cut, folded, or layered to create custom inserts that stabilise products and separate items within a package.
It’s recyclable and easy to source, lightweight yet sturdy, and can be customised for various products. Lots of fulfilment centres use them for home goods, appliances, and packaged food items.
6. Inflatable Dunnage
Inflatable dunnage bags are used to secure products in larger shipping containers to prevent movement during transport. This type of dunnage expands to fill empty spaces to brace cargo effectively.
It saves space before inflation, excellent for securing bulk shipments, and reduces risk of container load shifts. They are best used for palletised goods, bulk shipments, and international freight.
Choosing the Right Dunnage for Your Products
Selecting the right dunnage is about more than just protection. As a business, you need to think about balancing cost, product safety, and shipping efficiency.
- Assess Product Size, Weight, and Fragility: Different products require different levels of protection. Lightweight items, like clothing, might only need dunnage paper, while fragile glassware requires foam inserts or bubble wrap. Similarly, heavy machinery or furniture often benefits from wood dunnage for added stability.
- Match Dunnage to Shipping Methods: Air shipping often has stricter weight limits and requires lightweight materials like air pillows. Ground and sea transport, which involve longer transit times and more handling, may need sturdier materials such as wood or corrugated cardboard.
- Consider Cost and Operational Efficiency: Excessive dunnage increases costs. The goal is to find a balance between protection and cost-efficiency. Use multi-purpose and reusable dunnage (like cardboard or foam) for versatility, invest in a dunnage machine to automate air pillow or paper dunnage production, and regularly assess dunnage needs based on product trends to avoid overpacking.
The Environmental Impact of Dunnage
Dunnage is important for protecting products, but it also contributes to environmental waste if not carefully managed. Choosing eco-friendly alternatives helps businesses reduce their carbon footprint and align with consumer preferences for sustainability.
Eco-friendly dunnage options are:
- Dunnage Paper: 100% recyclable and biodegradable, provides lightweight protection, and decomposes naturally – reducing landfill waste.
- Corrugated Cardboard: Durable, recyclable, and reusable, cardboard is a popular choice for product cushioning and structural support.
- Biodegradable Air Pillows: Made from plant-based materials, air pillows break down faster than traditional plastic without leaving harmful residues.
- Recycled Foam Inserts: While foam is less eco-friendly, recycled versions help repurpose waste materials into protective packaging.
But aside from using eco-friendly dunnage, you can also reduce waste through smart dunnage use. Overpacking drives up costs and generates unnecessary waste. By optimising the amount of dunnage used, fulfilment centres can improve sustainability while maintaining product protection.
You can reduce dunnage waste by:
- Using packaging that fits the product snugly.
- Investing in automated dunnage machines.
- Reusing dunnage for multiple shipments.
Best Practices for Using Dunnage in Fulfilment Centres
Proper use of dunnage can improve packaging workflows, protect products, and reduce operational costs in fulfilment centres. By incorporating smart packing strategies and streamlining processes, businesses can achieve better outcomes while minimising waste.
1. Optimising the Use of Dunnage for Maximum Protection
Proper application of dunnage secures products during transit and reduces the risk of damage. However, it’s important to strike the right balance between protection and material usage.
Key strategies that fulfilment centres implement include:
- Using a combination of different dunnage types (e.g., paper and bubble wrap) to create multi-layered protection around fragile items.
- Filling empty spaces in packages to prevent items from shifting. Dunnage paper, air pillows, and corrugated inserts work well for this purpose.
- Using foam inserts and bubble wrap to absorb shocks, especially for delicate or electronic products.
2. Streamlining Dunnage into Packing Workflows
Efficiency in the packing process directly affects order fulfilment speed. Dunnage is integrated into packing stations to avoid delays and maintain consistency.
Packing areas are equipped with machines that produce air pillows or paper dunnage on demand to reduce manual effort and packaging time. Pre-cut dunnage sizes also speed up the packing process for standardised products.
Dunnage materials are also arranged within easy reach at packing stations, so packers can access the necessary supplies without disruption.
3. Reducing Packaging Material Waste
Excessive dunnage adds unnecessary costs and contributes to environmental waste. Fulfilment centres adopt practices that minimise material usage while maintaining effective product protection.
They use boxes that fit the product closely to reduce the need for excess void fill, develop standard packing procedures to ensure consistent use of dunnage across all orders, and always encourage reuse of undamaged dunnage materials. They also implement recycling programmes for packaging waste.
4. Training and Quality Control
Fulfilment centres also ensure that staff are trained in best practices for dunnage application. It is critical to maintaining packaging quality and efficiency. Regular quality checks can help identify areas for improvement.
Packing teams are educated on the importance of dunnage and how to use it effectively without overpacking. Periodic audits for packed orders are also carried out to verify dunnage application and product security.
The Future of Dunnage in E-commerce Fulfilment
There will always be a need for innovative packaging solutions that balance protection, efficiency, and sustainability in order fulfilment. Dunnage is a staple in e-commerce fulfilment processes, and it also experiences advancements driven by consumer demand, environmental concerns, and emerging technology.
1. The Push for Sustainable Dunnage
Dunnage is moving toward eco-friendly materials that reduce waste without compromising protection. Materials like cornstarch-based packing peanuts and biodegradable air pillows are becoming standard in eco-conscious fulfilment centres, like Green Fulfilment.
Paper-based fillers and corrugated inserts are replacing plastic and foam, offering fully recyclable options that align with green initiatives. Inflatable pillows or plastic inserts can be returned and reused as well.
2. Automation and Smart Dunnage Machines
Automation is transforming fulfilment centres, and dunnage application is no exception. Automated dunnage machines calculate the precise amount of dunnage required for each package.
Advanced scanners measure product dimensions and automatically create custom dunnage inserts to offer a perfect fit for delicate or irregularly shaped items. Machines that dispense air pillows or paper on demand help streamline packing workflows and improve productivity during peak seasons.
3. Advanced Dunnage Materials
The focus is on developing materials that offer superior cushioning while reducing bulk and weight. Some material innovations to look out for include:
- Expanded Polyethylene (EPE) Foam: This lightweight yet durable foam offers enhanced shock absorption, making it ideal for electronics and fragile items.
- Moulded Pulp Dunnage: Made from recycled paper, moulded pulp provides excellent cushioning and can be custom-shaped for specific products.
- Nanomaterials: High-strength, ultra-light materials with exceptional protective properties are in development and it promises to revolutionise dunnage for high-value shipments.
4. Customised and On-demand Dunnage
The shift toward personalisation in eCommerce extends to packaging. Fulfilment centres are embracing tailored dunnage solutions that fit individual products. It reduces the need for generic, one-size-fits-all materials.
Key developments include on-demand dunnage printing, inflatable dunnage, and modular and stackable dunnage boards.
5. Integration with Smart Packaging and IoT
Dunnage is becoming part of the larger smart packaging ecosystem. IoT-enabled packaging solutions are improving supply chain visibility and providing real-time data on product condition during transit.
Dunnage equipped with sensors can detect shocks or tilts, alerting shippers if products experience rough handling. For perishable goods, dunnage embedded with temperature monitoring technology helps ensure products remain within safe conditions. And QR codes on dunnage provide tracking and recycling instructions for better transparency and encouraging reuse.
Fulfilment centres, like Green Fulfilment, leverages smart packaging innovations to help businesses gain better insights into their supply chains and improve customer trust.
A Tailored Approach to Dunnage Solutions
Green Fulfilment understands that every business has unique needs and needs to adapt to evolving technology. That’s why we offer personalised dunnage solutions tailored to your specific product requirements. We work closely with you to identify the best options for maximum protection and cost-effectiveness.
Our expertise in selecting the right dunnage materials makes sure that your products are safe, your costs are optimised, and your customers are delighted.
Dunnage: The Key to Damage-free Deliveries
Understanding the various types of dunnage available can help you make informed decisions that protect their products while aligning with budget and sustainability goals. As fulfilment centres continue to evolve, the integration of automated dunnage machines, eco-friendly materials, and smart packaging solutions will drive even greater efficiency and innovation in the industry.
At Green Fulfilment, we recognise the importance of every element in the shipping and packaging process. We pack your products with care and optimise the order fulfilment process for the best customer experience possible.
Optimise your packaging and partner with Green Fulfilment today to revolutionise your order fulfilment process. Discover how our advanced and tailored dunnage solutions can protect your products, reduce costs, and support your sustainability goals.