Discover the Meaning of Dunnage

What is Dunnage & How Does It Relate to Packaging?

The dunnage meaning in the packaging world is the interior structure of a package that firmly holds the product into place. Basically, it’s the assembled material inside of any package that has been custom cut and built to the specifications of the part.

In this article, we will discuss a few different examples of dunnage and explain why they’re essential for packaging.

Hand Held Tote Dunnage

Hand held totes are standard plastic containers that come in various sizes. Typically, these totes will be utilized when the product that requires packaging is smaller and lighter. During the design stage, a unique style of the dunnage will be created to hold multiple parts for a greater logistics value.

The most common material used for these totes to form the interior dunnage is plastic corrugated. Ultimately, the plastic corrugated is cut to a custom size to form pockets and fastened inside of the tote for the product to rest in. As a result, a high quantity of the particular product can be loaded and unloaded inside of these pockets with ease, and can be transported safely between locations.

Bulk Container Dunnage

Bulk containers are essentially bigger containers that also come in various standard sizes. Due to the larger size, these containers are capable of packaging larger and heavier products. Basically, when a customer requires a package for a large part, a custom dunnage will be cut and placed inside of the container for the part to sit in comfortably.

Cross link foams are commonly utilized for the interior dunnage. To explain, a foam rail will be cut to the exact contour of the product to hold the product firm during transportation. In fact, there will be foam rails on both sides of the part to ensure the product doesn’t fall out of the dunnage when any sort of vibration occurs.

Steel Rack Dunnage

Steel racks are custom sized frames and are necessary for packaging, especially when the product is very heavy and large. Given that the previous options are not viable for oversized heavier parts, this robust option will be the most efficient to safely accommodate the product. Surely, a strong dunnage will be required to hold the weight of all the parts and this durable option works best.

There are many different types of dunnage that are used for the internal holding mechanism, but in this article we will focus on the steel cantilever solution. Essentially, this type of package can effectively provide the strength to hold multiple large products as the extruding steel dunnage can handle a heavy load. After all, products of all sizes require a packaging solution and welded steel frames like this will always be an amazing solution for the larger parts.





Plexform specializes in returnable packaging and material handling solutions such as custom steel racks and interior bulk container/tote dunnage. Our mission is to reduce transportation costs and product damage by producing custom packaging specifically tailored to each unique part.

Rack Repair

Fixing All Racks…

Design Engineering...

Innovative Design Concepts…


From Design To Build…

Need A Quote?

Contact Us Now For A Free Quote On Any Custom Packaging Product


Design engineer cost effective and robust products


Produce custom designed builds specific to each part

Design Gallery

View Our Design Gallery

Thumbs Up Clear