Dunnage

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Dunnage is one of those words that sounds old-school… until you realize it’s the reason your freight shows up intact (or shows up looking like it went 12 rounds with a forklift). If you ship anything—parts, pallets, drums, cartons, equipment, finished goods—dunnage is the “hidden structure” that keeps loads from shifting, crushing, rubbing, leaking, or turning into expensive returns.

And if you’re buying at truckload volume, you’re not shopping for random filler. You’re building a repeatable protection system for your supply chain.

This guide is going to cover what dunnage is, what types exist, when each type wins, how to choose the right dunnage for your loads, and how to stop wasting money on “stuffing material” that doesn’t actually solve the problem.

What Dunnage Actually Is (Plain English)

Dunnage is any material used to protect cargo during transport by filling voids, preventing movement, separating items, absorbing shock, and stabilizing loads.

If a shipment can move, it will move.

And when it moves, you get:

Dunnage is how you prevent that.

Think of it as the “internal architecture” of a shipment.

Why Truckload Dunnage Buying Is a Big Deal

When a company buys dunnage by the truckload, it usually means one of two things:

  1. They ship heavy volume and dunnage is a daily consumable

  2. They ship high-value product and they’re done gambling with damage

Truckload buying typically improves:

And standardization is the real win.

Because the most expensive dunnage is the dunnage you don’t have when you need it… or the dunnage that gets used wrong because it’s inconsistent.

Call or Text us at 832.400.1394 for a Quote!

The 5 Jobs Dunnage Must Do

If your dunnage doesn’t do at least one of these jobs, it’s not dunnage—it’s clutter.

1) Void fill

Fills empty space so items can’t shift.

2) Blocking and bracing

Stops loads from sliding, tipping, or collapsing.

3) Separation

Prevents item-to-item contact (scuffing, abrasion, denting).

4) Cushioning / shock absorption

Reduces impact damage.

5) Load stabilization

Keeps pallets and freight units “tight,” uniform, and resistant to vibration and handling.

Every dunnage type is just a different tool for one or more of those jobs.

The Big Mistake People Make With Dunnage

They choose dunnage based on what’s cheapest.

Bad move.

Because the real cost isn’t the dunnage.

The real cost is:

So you don’t buy dunnage to “save money on dunnage.”

You buy dunnage to reduce total cost of shipping damage.

The Main Types of Dunnage (And When Each One Wins)

Let’s break down dunnage like a buyer—not like a textbook.

1) Corrugated dunnage (pads, sheets, partitions)

This is the “most common” dunnage category because it’s:

Best for:

Where it fails:

2) Plastic dunnage (corrugated plastic, plastic sheets, reusable pads)

This is the “upgrade” when you need:

Best for:

Where it fails:

3) Foam dunnage (poly foam, PE foam, custom foam inserts)

Foam is for when:

Best for:

Where it fails:

4) Air dunnage (air pillows, inflatable void fill, air bags)

Air-based dunnage is a speed tool.

Best for:

Where it fails:

5) Paper dunnage (kraft paper, crumpled paper, honeycomb paper)

Paper dunnage is great when:

Where it fails:

6) Wood dunnage (lumber blocking, bracing, wedges)

Wood is for serious stability.

Best for:

Where it fails:

7) Molded dunnage (custom reusable racks, trays, inserts)

This is the “enterprise move.”

Best for:

Where it fails:

Call or Text us at 832.400.1394 for a Quote!

The Dunnage Decision Framework (Stop Guessing)

If you want to choose the right dunnage in one shot, answer these questions:

1) What is the product?

2) What’s the failure mode?

3) How is it shipped?

Each method has a different abuse profile.

4) What’s the environment?

5) Is it one-way or returnable?

Returnable loops unlock reusable dunnage economics.

Once you answer these, the right dunnage type becomes obvious.

“Badass” Dunnage Comparison Table

Here’s a simple practical chart.

Need Best Dunnage Type Why
âś… Fill empty space in cartons fast Paper or air dunnage Fast void fill and easy packout
âś… Stop pallet layers from scuffing Corrugated pads or plastic sheets Separation + surface protection
✅ Moisture/humidity resistance Plastic dunnage Doesn’t soften like paper
âś… Protect fragile parts Foam or molded inserts Cushions and holds shape
âś… Brace heavy industrial loads Wood blocking/bracing Real structural restraint
âś… Repeat lanes, low damage goal Molded reusable dunnage Consistent fit + repeat use

Dunnage for Pallets (Where the Big Money Gets Saved)

Most shipping damage happens on pallets, not inside individual cartons.

Why?
Because pallets get:

Dunnage for pallets usually means:

If your pallet has uneven layers, you’re basically begging for damage.

A flat, uniform pallet with proper dunnage and proper wrap survives much better.

Dunnage for LTL (Where Things Get Ugly)

LTL is touch-heavy:

That means you need dunnage that can handle:

If you have LTL damage issues, the solution is rarely “stronger box only.”
It’s usually:

Dunnage for Export and Containers

Containers introduce long dwell times, vibration, and sometimes moisture.

The dunnage strategy needs to account for:

This is where moisture-resistant dunnage and serious bracing becomes more important.

Call or Text us at 832.400.1394 for a Quote!

The 17 Most Common Dunnage Mistakes (That Cause Damage)

  1. Using void fill when you actually needed blocking/bracing

  2. Using light dunnage for heavy loads (it compresses and fails)

  3. Not protecting sharp edges (they cut dunnage and packaging)

  4. Overstuffing cartons (crush risk increases)

  5. Underfilling cartons (movement still happens)

  6. Ignoring vibration (product rubs, labels scuff)

  7. Not using top caps on pallets (top layer gets destroyed)

  8. No bottom protection (pallet deck boards cause damage)

  9. Overhang on pallets (corner crush factory)

  10. Assuming stretch wrap replaces bracing (it doesn’t)

  11. Using inconsistent dunnage (packers improvise)

  12. Not standardizing pack methods

  13. Not training the warehouse team

  14. Choosing the cheapest option without measuring damage cost

  15. Not planning for humidity/cold storage

  16. Not accounting for returnability if you could reuse

  17. Not tracking claims and tying them to packout changes

Fix these and damage drops.

A Simple Dunnage “System” You Can Implement

If you want a clean baseline for palletized shipments:

  1. Bottom protection (pad/sheet)

  2. Uniform layer pads between tiers (if layers aren’t naturally flat)

  3. Corner protection for sensitive loads

  4. Top cap on every pallet

  5. Blocking/bracing for loads that slide or tip

  6. Wrap technique standardized (same number of wraps, same tension)

That system is simple, repeatable, and measurably reduces problems.

Truckload Dunnage Buying: What to Standardize

When you buy dunnage by the truckload, standardize these:

This turns dunnage into a predictable input instead of a constant “where do we find something to fill this gap?” scramble.

The Quote Checklist (Copy/Paste This)

Want a fast quote and the right dunnage?

Send:

  1. Product type + weight

  2. Shipping method (parcel/LTL/TL/export)

  3. Failure mode (shift, crush, scuff, puncture, tip)

  4. Pallet size and typical stack pattern

  5. Environment (dry, humid, cold storage)

  6. One-way vs returnable program

  7. Truckload cadence (how often you need supply)

That’s enough to recommend the correct dunnage category and size plan.

Bottom Line

Dunnage is the invisible difference between a load that arrives clean and a load that arrives like a problem.

When you buy at truckload volume, you’re in the perfect position to standardize dunnage, speed up packout, stabilize pallets, and cut damage costs. And once you build a dunnage system, you stop paying the “random shipping damage tax” that most companies accept as normal.

Call or Text us at 832.400.1394 for a Quote!