Best Type of Dunnage to Use for Every Product, Optimal Methods for Ecommerce Fulfillment

Last Updated: July 24, 2024

Dunnage is the packing material used to protect products for shipping, but dunnage can do a lot more than just protect. For ecommerce brands, it is the first thing that their customers see when unboxing their new product, and dunnage is also tied directly to your overall cost of shipping.   

These factors make it imperative to analyze what the best type of dunnage is for your product, keeping in mind:   

• Customer expectations   
• Sustainability values  
• Product security   
• Cost to purchase, store, and use  
• How it affects shipping costs   
• Overall look and feel   

Here is a comprehensive list of types of ecommerce products and the best dunnage materials for each. If you outsource fulfillment to a 3PL, they should be able to help you source the best packing material for your brand and product and work with any custom dunnage you choose.    

Types of Dunnage Type Best for Every Type of Ecommerce Product

1. Fragile Items (e.g., Glassware, Ceramics, Electronics) 

Best Materials:  

• Bubble Wrap: Provides cushioning and absorbs shocks.  
• Foam Peanuts (also called packing peanuts): Fills voids and prevents movement within the box.  
• Air Cushions: Protect against impact and vibrations.  
• Packing Paper (also called kraft paper): Adds an extra layer of protection and prevents scratches.  
• Corrugated Paper Insets: Keeps items separated and adds structural support.  

2. Heavy Items (e.g., Machinery, Tools, Books) 

Best Materials:  

• Double-Walled Corrugated Boxes: Offers extra strength to support heavy weights.  
• Foam Inserts: Custom-cut foam provides support and protection.  
• Edge Protectors: Protect corners and edges of heavy items.  
• Pallets and Stretch Wrap: For very heavy or bulk items, pallets combined with stretch wrap secure the load.  
• Metal or Solid Plastic: Very strong to keep heavy items protected.   

3. Perishable Items (e.g., Food, Pharmaceuticals)  

Best Materials:  

• Insulated Shipping Containers: Maintains temperature control.  
• Gel Packs/Dry Ice: Keeps items cold or frozen.  
• Vacuum Sealed Bags: Extends shelf life by reducing air exposure.  
• Moisture Barrier Bags: Protects from humidity and moisture.  
• Wood Dunnage or Solid Plastic: Protects soft items like fruit or cake   

4. Clothing and Textiles  

Best Materials:  

• Poly Mailers: Lightweight and durable for non-fragile items.  
• Tissue Paper: Prevents wrinkles and adds a touch of presentation.  
• Plastic Bags: Keeps items clean and dry during transit.  
• Garment Bags: For high-value or delicate clothing items.  

5. Documents and Small Items (e.g., Books, Jewelry)

Best Materials:  

• Padded Envelopes: Protects against minor impacts.  
• Rigid Mailers: Prevents bending of documents.  
• Bubble Mailers: Combines the benefits of padding and mailing envelopes.  
• Small Boxes with Dividers: Keeps small items organized and protected.  

6. Large and Irregularly Shaped Items (e.g., Furniture, Musical Instruments)  

Best Materials:  

• Custom Crates: Provides maximum protection and support.  
• Foam Padding: Custom cut to fit the shape of the item.  
• Stretch Wrap: Secures parts and adds a layer of protection.  
• Corner Protectors: Protects edges from damage.  

Dunnage Solutions for Safe Shipping and Damage Protection 

The last thing you want as an ecommerce brand is to put your products in beautifully branded packaging, only to realize it doesn’t keep your items safe in transit. Reports of damaged or broken products is a big issue and can result in customer dissatisfaction and lost revenue.  

Take into account the empty spaces within your overpack, the shock absorption you’ll need (as shippers may not handle items with care, and how cost-effective the different types of dunnage are in relation to the overall cost of your items.  

Ensure it meets all the necessary requirements. When using branded boxes or specialty dunnage, you’ll need to ensure it can accommodate any labeling or shipping criteria. Take the transportation mode into consideration for product security also. If your goods need Dangerous Goods labels, those need to be prominent and highly visible.   

Correctly use each packing material type. Each type of dunnage will have specified instructions for ensuring it fills the package properly to maximize safety. Sometimes this might even be included in your fulfillment work instructions. For example, air pillows come in different sizes and weights, the amount of air pressure added (PSI) will vary. More air than necessary the cushions will pop and less air will mean they may not keep your products as secure.   

Monitor and analyze your products. Take a multi-faceted approach to monitoring how your dunnage choices are doing—take a pulse of your customer satisfaction, especially regarding product damages or related issues, and make a point to regularly ship products to your own office. It’s the only sure way you’ll be able to spot check how your 3PL is packaging up your items.   

Bottom Line   

To some ecommerce brands, packaging options may seem like an afterthought, but it is an integral part of your budget, product security, and customer satisfaction. Proper dunnage can ensure sensitive items get through your supply chain intact, and custom dunnage solutions (like reusable or eco-friendly materials) can be a way to connect and engage with your customers. Your packaging materials need to be the right dunnage to match your brand ethos and customer expectations, but above all it needs to be exactly the right fit for your product.   

Tags: Packaging