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Dunnage is any material used to protect, cushion, block, brace, or stabilize a product during shipping and storage so it doesn’t move, rattle, tip, rub, puncture, or get crushed.
In simple terms: dunnage is the “stuff” that keeps your freight from getting destroyed.
If packaging is the container, dunnage is the control system inside and around it that makes sure the load survives real-world abuse—forklifts, vibration, drops, stacking pressure, sharp edges, and the kind of handling nobody admits to.
Now let’s break down what dunnage is, what it does, the different types, and how to choose the right dunnage so your shipments stop arriving looking like they got mugged in transit.
What dunnage is used for (the 5 jobs)
Dunnage exists to do five jobs:
1) Block & brace
Stops product from shifting. This is huge for pallets, crates, and containers.
2) Cushion shock
Absorbs impact from drops and handling.
3) Prevent abrasion
Stops rubbing and scuffing between units.
4) Distribute load
Spreads weight so you don’t crush corners, dent product, or collapse stacks.
5) Fill voids
Eliminates empty space so product can’t build momentum inside a box or crate.
If your freight is moving inside the package, your dunnage isn’t doing its job.
Dunnage vs. void fill (quick difference)
People mix these up.
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Void fill is a type of dunnage used specifically to fill empty space.
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Dunnage is the umbrella term that includes void fill plus blocking, bracing, cushioning, and separators.
So: all void fill is dunnage, but not all dunnage is void fill.
The main types of dunnage (and where each one wins)
1) Corrugated Pads / Chipboard Pads
What it does: Separates layers, distributes weight, protects surfaces.
Best for:
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palletized boxes
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stacking strength
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layer separation
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preventing carton crushing
This is one of the most underrated dunnage types because it boosts stack strength and reduces damage fast.
2) Honeycomb Pads
What it does: Heavy-duty load distribution and shock absorption.
Best for:
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heavier products
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high stacking pressure
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protecting against compression damage
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transit packaging for industrial shipments
Honeycomb is like “chipboard on steroids” when you need real strength.
3) Foam (Sheets, Inserts, Blocks)
What it does: Cushions, immobilizes, protects delicate surfaces.
Best for:
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fragile items
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high-value products
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electronics, parts, medical items
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custom protection inside crates or cartons
Foam is what you use when “no damage” isn’t a preference—it’s a requirement.
4) Kraft Paper / Packing Paper
What it does: Void fill + blocking/bracing when packed correctly.
Best for:
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medium-weight products
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general shipping
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operations wanting paper-based dunnage
Paper is cheap and effective when used generously. When used lightly, it’s a placebo.
5) Air Pillows
What it does: Fills space quickly and prevents movement (light items).
Best for:
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lightweight products
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high-speed packing lines
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filling large voids
Not good for heavy products or sharp edges.
6) Loose Fill (Peanuts)
What it does: Fills irregular voids.
Best for:
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odd-shaped products
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certain low-risk shipments
Messy, shifts over time, and customers often hate it.
7) Wood Blocking / Bracing
What it does: Locks heavy loads inside crates and containers.
Best for:
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machinery
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heavy industrial items
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container shipping
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preventing shifting
This is “real” dunnage—used when freight movement would be catastrophic.
8) Inflatable Dunnage Bags (Container/Truck Bags)
What it does: Fills gaps in trailers/containers to prevent load shift.
Best for:
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container shipping
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truckload freight
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palletized loads with gaps
These are massive in logistics because load shift causes damage and accidents.
9) Slip Sheets / Tier Sheets
What it does: Clean separation between layers, smoother handling, faster load moves.
Best for:
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pallet layers
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warehouse efficiency
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keeping product clean
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reducing friction damage
Tier sheets are dunnage in the purest form: simple, cheap, and powerful.
10) Liners (Gaylord Liners, Drum Liners, Bulk Bag Liners)
What it does: Containment, cleanliness, moisture protection.
Best for:
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powders
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granules
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messy materials
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contamination-sensitive products
Liners are dunnage when the enemy is moisture, dust, or contamination.
Where dunnage is used (common scenarios)
Dunnage is used in:
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Boxes (void fill, foam, pads)
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Pallet loads (layer pads, edge protectors, tier sheets)
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Gaylords (liners, pads, separators)
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Crates (foam + wood blocking + bracing)
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Containers and trailers (inflatable dunnage bags, bracing)
If something is being shipped, dunnage is usually part of the protection system—even when people don’t call it that.
The most common dunnage mistake
Here it is:
Using the wrong dunnage for the weight.
Light product can get away with air pillows.
Heavy product needs structure—pads, foam, bracing, blocking.
If you ship a heavy item with “fluffy” dunnage, it will compress, shift, and fail.
How to choose the right dunnage (simple framework)
Answer these:
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How heavy is the product?
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How fragile is it?
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What damage is most likely—impact, compression, abrasion, or shift?
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Is the shipment palletized, boxed, or crated?
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Is it LTL (more handling) or truckload (less handling)?
Then choose:
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Impact risk → foam / honeycomb / bubble
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Compression risk → honeycomb / corrugated pads / edge protection
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Shift risk → blocking & bracing / dunnage bags
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Abrasion risk → pads / separators / wraps
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Void space → paper / pillows / loose fill (as appropriate)
Bottom line
Dunnage is the material used to protect and stabilize products during shipping and storage—preventing movement, absorbing shock, distributing weight, and reducing damage.
It’s not optional if you care about:
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fewer claims
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fewer returns
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cleaner deliveries
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safer shipments
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happier customers