What Is Dunnage Insertion? Purpose, Materials, and Best Practices

Adding protective filler materials such as paper, air pillows, foam, or corrugate to reduce movement and damage.

Dunnage Insertion Adding protective filler materials such as paper, air pillows, foam, or corrugate to reduce movement and damage. Dunnage insertion is the practice of placing void-fill and protective materials inside shipping cartons, cases, crates, and interstitial spaces on pallets to prevent product movement during handling and transport.

Dunnage insertion protects goods against three common threats in distribution networks: impact forces from rough handling, repeated vibration during transit, and shifting caused by braking or cornering. The technique is used across warehousing, e-commerce fulfillment, and full-container ocean shipments. A correct dunnage insertion strategy balances protection, cost, weight, and sustainability.

Common Materials Used For Dunnage Insertion

Different materials suit different products, transport modes, and sustainability priorities. Choose materials based on cushioning ability, compressive strength, moisture sensitivity, and compatibility with automated packing systems.

• Paper: Crumpled kraft or bonded paper provides variable cushioning, is recyclable, and works well for light-to-medium items.
• Air Pillows: Lightweight inflatable cushions offer excellent void fill with low material weight but require proper sealing and can puncture.
• Foam: Polyethylene or polyurethane foams deliver predictable compression and are useful for fragile electronics and irregular shapes.
• Corrugate: Layered or die-cut corrugate pieces are strong for bracing and blocking on pallets and within crates.
• Wooden Dunnage Blocks: Used where high compressive strength or load-bearing bracing is necessary, including for heavy industrial equipment.
• Biodegradable Options: Mushroom-based or starch-based fillers exist where compostability and sustainability are priorities.

Why Dunnage Insertion Matters

Damage is expensive: product replacement, returns processing, and customer dissatisfaction all add cost. Dunnage insertion reduces damage-related costs by limiting movement and providing controlled deformation zones. It also preserves pack integrity so downstream processes — scanning, sorting, and automated picking — operate reliably.

How To Design An Effective Dunnage Insertion Strategy

Designing a strategy starts with risk assessment and a few simple measurements. Consider product fragility, density, void ratio, and expected transport stress (road miles, pallet stacking, sea voyages). From there create standardized pack specs with target void fill percentages and minimum cushion thicknesses.

• Measure: Record product dimensions, weight, and fragility rating to calculate void volume and cushion requirements.
• Specify: Create SKU-level packaging instructions: material type, placement (top, bottom, sides), and minimum amount.
• Test: Run drop and vibration tests for fragile SKUs or for export lanes with high handling risk.
• Document: Add dunnage steps to packing checklists and WMS pick-pack screens to enforce consistency.

Operational Considerations

Practical implementation touches packing ergonomics, throughput, and automation. For high-volume e-commerce operations, automated baggers and air pillow machines reduce labor and increase repeatability. For palletized LTL and FCL shipments, corrugate bracing and wood blocks may be needed to resist lateral forces.

• Speed Vs. Protection: Heavier-duty dunnage increases pack time and material costs; evaluate damage rates to justify spend.
• Automation: Integrate air-pillow and foam-in-place machines where consistent insertion is required.
• Storage: Keep dunnage dry and accessible; some materials become ineffective if wet or compressed for long periods.

Cost, Weight, And Sustainability Trade-Offs

Dunnage adds materials, weight, and sometimes volume — all of which affect shipping cost. Lightweight options like air pillows often reduce dimensional weight penalties, while heavier wood or foam increase freight costs. Consider lifecycle impacts: recyclable paper and corrugate usually score better on sustainability metrics than virgin plastic foam.

Quality Control And Metrics

Track damage rates, pack time per order, material usage per shipment, and return reasons to measure your dunnage program’s effectiveness. Use periodic audits of packing stations and random load inspections before carrier pickup. Update specifications if damage persists for an SKU or lane.

Tips For Warehouse Implementation

• Standardize: Create easy-to-follow pack cards for each SKU family to reduce operator variation.
• Train: Teach packers how much fill is enough — both under- and over-filling are costly.
• Right-Size Boxes: Reducing void space often reduces the need for dunnage altogether.
• Audit: Run quarterly quality checks tied to packer performance and carrier claims.

In short, the Dunnage Insertion technique of adding protective filler materials such as paper, air pillows, foam, or corrugate to reduce movement and damage is a practical, often low-cost way to cut claims and keep goods ship-ready. A well-specified program that balances protection, cost, and sustainability reduces damage, lowers returns, and keeps fulfillment flowing smoothly.