What Is Dunnage? Why It’s Essential in Ecommerce Shipping
by Jaidyn Farar
Even inexperienced shippers know that when sending a fragile or expensive product, you can’t just stick it into a box and send it on its way. To protect it during transit, you need to add the right dunnage (or cushioning material). But choosing dunnage isn’t as straightforward as it might sound.
This article will walk through the pros and cons of various types of dunnage, as well as a few tips for selecting the right cushioning material for each package you ship.
What is dunnage?
Dunnage is the protective material used to keep goods secure during shipping. It fills the empty spaces in a package (or in delivery vehicles, for freight shipments) so that items don’t shift and become damaged during transit.
By absorbing shocks, keeping loose components in place, and shielding against environmental factors like dust and moisture, dunnage helps ensure that your products arrive at their destination intact. The result? Satisfied customers, fewer returns, and a stellar brand reputation.
Types of dunnage
When choosing dunnage, you need to weigh many factors: cost, sustainability, durability, and more. Let’s take a look at some of the most common protective materials, including their benefits and potential downsides.
Bubble wrap
Bubble wrap is a lightweight plastic material featuring rows of air-filled bubbles. The bubbles create a cushioning barrier that effectively absorbs shocks, preventing damage from rough handling. Bubble wrap comes in several different forms, including standard rolls, adhesive-backed sheets, and even anti-static versions.
Many merchants rely on bubble wrap when shipping products like glassware, ceramics, electronics, and other fragile goods.
Pros of bubble wrap:
- Provides excellent cushioning and shock absorption
- Lightweight, which reduces shipping costs
- Low-cost
Cons of bubble wrap:
- Not eco-friendly unless made from recycled or biodegradable materials
- Not ideal for filling large empty spaces
Air pillows
Air pillows are plastic, air-filled bags that come in different sizes and configurations. Unlike bubble wrap, which usually wraps tightly around a product in one or more layers, air pillows are designed to fill large voids in packages.
Air pillows are useful when shipping packages containing lightweight or non-fragile items like books, clothing, or boxed goods. If you’re shipping fragile items, make sure to pair air pillows with a secondary layer of protection.
Pros of air pillows:
- Lightweight and space-efficient before inflation
- Ideal for filling large empty spaces
Cons of air pillows:
- Not ideal for delicate or irregularly shaped items
- Usually made of plastic, though some biodegradable options exist
Paper and cardboard
While bubble wrap and air pillows are affordable and effective, they have a major flaw: since they’re usually made of plastic, they’re not an environmentally friendly option. For a greener approach, many businesses have opted to use paper and cardboard-based dunnage when possible.
In addition to being recyclable (or made from recycled materials), paper and cardboard are cost-effective and versatile. The following are just a few options you can choose from:
- Kraft paper. Kraft paper is a sturdy brown paper often used for wrapping products or crumpling to fill empty spaces in packages. Its strength and flexibility make it a great choice for protecting lightweight items during transit.
- Shredded cardboard. As a sustainable alternative to packing peanuts, shredded cardboard is great for void filling and product padding. It’s especially useful for businesses looking to recycle their packaging waste.
- Corrugated cardboard. Corrugated cardboard, with its strong inner layer, provides better strength and shock absorption than standard cardboard. It also offers good protection against moisture and condensation. It’s often used as inserts, dividers, or custom-cut panels to protect large or heavy items.
Pros of paper and cardboard dunnage:
- Sustainable and recyclable
- Lightweight, which reduces shipping costs
- Cost-effective and easy to source
Cons of paper and cardboard dunnage:
- Provide limited protection for very delicate items
- May require large quantities to fill voids adequately
Foam
Foam dunnage comes in many forms, including sheets, rolls, blocks, and molded inserts. And of course, we can’t forget one of the most common types of foam dunnage out there: packing peanuts.
Foam is particularly useful for shipping high-value or very fragile items like electronics, medical equipment, and precision tools. Merchants selling these products often purchase custom-molded foam inserts to make sure every component is protected during shipping.
Pros of foam dunnage:
- Great cushioning and shock absorption
- Can be custom-molded for a precise fit
Cons of foam dunnage:
- Bulkier than other dunnage types
- Can be expensive, especially for custom solutions
- Often made from non-biodegradable materials, though some eco-friendly options are emerging
Solid plastic
Solid plastic dunnage is most often used in freight shipping, particularly for large, heavy loads like automotive parts, industrial equipment, or bulk goods. Rigid, durable plastic can be used to stack items securely or separate them to prevent damage from weight or vibration.
Pros of solid plastic dunnage:
- Durable and reusable, offering long-term cost savings
- Resistant to moisture, chemicals, and extreme temperatures
Cons of solid plastic dunnage:
- High initial cost compared to disposable options
- Bulky and heavy, which may increase shipping weight
Wood
Like solid plastic, wood dunnage is often used to secure and stabilize heavy freight shipments. It typically takes the form of braces or blocks and is valued for its strength and availability. It’s also a budget-friendly option compared to materials like plastic.
Pros of wood dunnage:
- Strong and reliable for heavy loads
- Readily available and cost-effective
- Can often be repaired and reused
Cons of wood dunnage:
- Susceptible to moisture, rot, and pests
- Not as durable or long-lasting as plastic
Benefits of using the right dunnage in shipping
Why bother with dunnage? And why not just use the same cushioning material for every shipment?
While forgoing dunnage—or always using the same type—would make order fulfillment simpler, it could also lead to some major shipping disasters. On the other hand, choosing the right dunnage will protect products, keep costs low, and win you points with customers.
Protection from damage and moisture
The most important role of dunnage is safeguarding products from damage by preventing them from shifting or colliding. Despite all of a shipping carrier’s precautions, packages are sometimes dropped or otherwise handled roughly. Dunnage absorbs unexpected shocks and keeps products secure in the center of their boxes, out of harm’s way.
For moisture-sensitive goods, dunnage materials like plastic or treated paper can be used to form a barrier against damp conditions. This is especially valuable for perishable goods, electronics, and other products prone to damage from water exposure.
Lower shipping costs
When it comes to keeping products safe, you don’t want to cut corners. But on the flip side, it’s important (for your customers’ wallets and your own) to keep shipping costs as low as possible. Being strategic about cushioning material helps you save money and pass those savings on to buyers.
By using lightweight dunnage options, you can keep package weights down and avoid having to pay higher shipping rates. On a similar note, you’ll want to consider whether your chosen filler material is bulky enough to require larger boxes. Since most carriers use dimensional pricing, an unnecessarily large box will drive up costs. And of course, the cost of the dunnage material itself factors in; some types are more expensive than others.
Ultimately, your dunnage should be optimized for effectiveness, cost, package size, and weight. It’s a lot to think about, yes, but it’s a great opportunity to boost the overall cost-efficiency of your parcel shipping.
Lower return costs
Returns due to damaged items can significantly impact profitability. Fortunately, effective dunnage reduces the likelihood of product damage, cutting down on returns. That means less money spent on processing, restocking, and reshipping items.
Improved customer satisfaction
Nothing disappoints a customer more than receiving damaged goods. Dunnage keeps products safe and intact, leading to happier and more loyal customers. These satisfied customers are more likely to leave positive reviews, make repeat purchases, and recommend your business to others.
Remember, you may have just one chance to build trust with a customer. By packaging items properly, you show your attention to detail and commitment to customer satisfaction. Over time, you’ll win the trust of more and more satisfied buyers.
Greater sustainability
Consumers today are more aware of sustainability concerns than ever before. As a result, many of them cringe when they open a package to reveal layers of bubble wrap, handfuls of foam packing peanuts, or other non-sustainable materials.
While dunnage materials like foam and plastic may have their place in a successful fulfillment strategy, brands also have a chance to show customers they’re taking extra steps toward eco-friendly operations. You can use biodegradable plastics, recyclable paper, or even reusable filler materials—the possibilities are endless!
By choosing eco-friendly dunnage, you’ll reduce your environmental impact and appeal to eco-conscious customers.
Learn more about sustainable packaging here.
Choosing the best dunnage for every shipment
Now that you know your options for dunnage—and the importance of being strategic with your choices—let’s cover a few tips for optimizing every package you send.
- Balance quality and cost. When choosing dunnage, aim to strike a balance between effectiveness and affordability. While premium materials like custom-molded foam offer near-perfect protection, they’re not necessary for all shipments. Evaluate the value of your goods and the level of protection required to make sure you’re not overspending.
- Consider each item that’s being shipped. Not all products have the same shipping needs, so match your dunnage choice to the specific requirements of each item. Fragile items will probably require cushioning materials like bubble wrap or foam, while sturdy, stackable goods might only need void fillers like air pillows.
- Pair dunnage with the right outer container. The effectiveness of dunnage often depends on the packaging it’s paired with. A sturdy cardboard box works well with most dunnage materials, while poly mailers might only need minimal wrapping for lightweight items.
Keep your shipments safe with EasyPost
Once you’ve chosen the most effective dunnage, packed your shipments, and handed them off to the carrier, you’re relying on the carrier to handle packages carefully and deliver them to the right addresses. And unfortunately, some of your shipments will be lost, stolen, or damaged. To protect your business financially—and make it easier to handle customer concerns—consider adding shipping insurance.
EasyPost’s comprehensive shipping insurance costs just 1% of a package’s value, regardless of destination. With a hassle-free claims process, EasyPost gives merchants peace of mind that even when the worst happens, they won’t lose money.