Dunnage is the protective filler that keeps your products safe during shipping, whether that means bubble wrap, kraft paper, foam peanuts, or custom inserts. The right dunnage lowers damages, reduces returns, and saves margins. Itâs essential for any ecommerce warehouse, especially if you rely on pick and pack warehouse workflows or advanced kitting and assembly services. ShipBots even includes eco-friendly options in its fulfillment pricing so you can focus on growth instead of packing materials.
If youâve ever unboxed a package filled with bubble wrap, kraft paper, or those clingy foam peanuts, youâve already dealt with dunnage. Itâs not just fluff, itâs the protective layer that prevents products from arriving broken, soggy, or scuffed.
At its simplest, dunnage does three things:
Without it, even the best warehouse shipping strategy collapses.
Imagine paying for returns, reships, and refunds because a candle cracked or a bottle leaked. Painful, right? Product damage is one of the leading reasons for ecommerce returns, which already hover around 20% according to the National Retail Federation.
Dunnage isnât a ânice-to-haveâ, itâs central to customer satisfaction and profit margins. For fast-growing brands using subscription box fulfillment or scaling through Shopify fulfillment, reliable packaging makes the difference between five-star reviews and angry emails.
And letâs be honest: customers notice. Unboxing is part of the shopping experience now. If your packaging screams âafterthought,â your brand reputation takes the hit.
When it comes to ecommerce packaging, dunnage isnât one-size-fits-all. The right choice depends on your products, your margins, and even your brand values (sustainability, anyone?). Below, weâll unpack the most common types of dunnage used by ecommerce warehouses and fulfillment centers today, complete with pros, cons, and where each shines.
Hard plastics are the heavyweights of protective packaging. Theyâre strong, durable, and built for high-value or bulky items like automotive parts or industrial equipment. The catch? Theyâre pricey and not exactly eco-friendly. Enter bioplastics. These are derived from plant-based materials like cornstarch or sugarcane, making them compostable and less harmful in landfills. Brands concerned about sustainability but still needing industrial-grade protection often look to bioplastics as a middle ground.
Ah, bubble wrap. The most iconic dunnage material and the bane of parents everywhere whoâve had kids stomping on it for fun. Cheap, flexible, and reliable, bubble wrap is perfect for fragile items like glassware, ceramics, or electronics. Itâs reusable, but unless recycled properly, itâs not great for the environment. That said, its protective qualities mean itâs still widely used by pick and pack fulfillment centers.
This eco-friendly twist takes post-consumer recycled cardboard and turns it into cushioning that mimics bubble wrapâs shock absorption, without the plastic guilt. Itâs compostable, lightweight, and sustainable, making it a win for brands committed to green practices. Perfect for subscription boxes or eco-conscious direct-to-consumer fulfillment.
The workhorse of the packaging world. Corrugated paper is strong, recyclable, and surprisingly versatile. It can support light to medium-weight goods, guard against moisture, and double as void fill. For ecommerce brands, corrugated paper is often the first step toward balancing protection and sustainability.
Think of kraft paper as corrugated paperâs laid-back cousin. Itâs inexpensive, recyclable, and endlessly adaptable. Crumpled kraft is used as void fill, while sheets can wrap fragile items. Plus, it creates a more natural unboxing vibe than foam or plastic. Many apparel fulfillment companies use kraft paper to wrap delicate fabrics without adding much weight.
These lightweight pouches are filled with, you guessed it, air. Theyâre cost-effective, space-saving in storage, and reduce dimensional shipping weight (a big deal when UPS or FedEx starts charging based on box size). Perfect for keeping items from shifting around during warehouse shipping. The downside? If one pops, protection is compromised.
Wooden dunnage isnât showing up in your monthly subscription box. Itâs used for creating barriers or supports between heavy products like furniture, engines, or construction materials. Pallets, braces, or blocks keep goods stable during long hauls. Reliable, but not remotely eco-friendly unless reclaimed.
Steel dunnage is rare in ecommerce but critical for industrial freight. Imagine moving turbines, engines, or multi-ton machinery, steel inserts and bracing are sometimes the only safe option. If your products need steel dunnage, youâre probably not running a Shopify store.
Foam dunnage comes in multiple flavors: peanuts, pads, sheets, or custom cutouts. Itâs lightweight, cheap, and protects delicate items like electronics or medical devices. Downsides? It can be messy, static-charged, and wasteful unless recycled. Some brands now opt for biodegradable âcornstarch peanutsâ as a greener alternative. Foam is often paired with kitting and assembly services to organize complex product bundles.
Sometimes your product doesnât fit neatly into bubble wrap or kraft paper. Thatâs where custom dunnage shines. Whether itâs branded inserts for luxury goods, precision-cut foam for medical devices, or eco-friendly cardboard structures for oddly-shaped products, custom packaging is both protective and a branding opportunity. Done well, it elevates the customerâs unboxing experience, turning packaging into a marketing channel.
Not every product is created equal, and neither is the packaging that protects it. The best dunnage for your store depends on what you sell, how often you ship, and the kind of experience you want customers to have when they open the box. Hereâs how different ecommerce niches approach protective packaging.
Clothing might not be fragile, but presentation is everything. Lightweight options like crumpled kraft paper or corrugated inserts help prevent wrinkles, moisture damage, and messy-looking shipments. Many apparel fulfillment companies already include these eco-friendly materials in their workflows, striking the right balance between protection and aesthetics.
For fashion brands, dunnage isnât just about preventing damage, itâs part of the unboxing experience. A chic tissue wrap or neatly placed kraft fill signals quality and care. In a market where customer retention is tied to brand loyalty, details like this matter as much as the product itself.
With subscription models, youâre shipping more frequently, which means packaging isnât a one-off, itâs part of the brand. Customers expect consistency. Thatâs why subscription box fulfillment relies on dunnage thatâs both protective and eco-conscious. No one wants a pile of waste building up every month.
Corrugated paper, compostable fillers, or even branded inserts serve double duty here: they keep items safe while reinforcing brand identity. Think of dunnage as stage design. Every time a customer lifts the lid, youâre delivering both a product and an experience.
For small to mid-sized brands scaling quickly, dunnage ties directly into Shopify fulfillment. Shipping carriers often charge based on dimensional weight, so the right filler keeps products secure without ballooning costs. Inflatable air pillows, kraft paper, and corrugated wraps are popular because theyâre protective but lightweight.
On top of that, packaging quality affects reviews. A well-packed order means fewer damages, fewer returns, and more five-star ratings on Shopify stores. Translation: less customer service overhead and stronger lifetime value.
When it comes to laptops, smartphones, or glassware, thereâs zero room for error. Foam inserts, bubble wrap, and air pillows are essential for absorbing shocks and preventing breakage. Even minor jostling can ruin expensive electronics, and one broken device equals a costly replacement.
Moisture protection also matters. Anti-static foam and sealed air cushions can safeguard against both impact and environmental risks like humidity. Ecommerce brands shipping fragile or high-value items often combine dunnage with kitting and assembly services to create customized protective bundles that travel safely from warehouse to doorstep.
Protective packaging isnât free. But not using it is far costlier.
Want to see how it impacts the math? Run the numbers with these supply chain formulas to understand how packaging efficiency affects your bottom line.
Nearly 80% of shoppers say sustainability influences buying decisions (McKinsey). Thatâs a big deal.
Eco-friendly dunnage options, corrugated paper, compostable fillers, bioplastics, are becoming the standard. And for brands importing through the ports of Los Angeles and Long Beach, stricter environmental guidelines make this shift non-negotiable.
Think of dunnage as one gear in the bigger logistics machine. It shows up at multiple stages:
Packaging is evolving alongside fulfillment. Expect:
For a broader perspective, check out the top fulfillment trends shaping 2025.
You donât need to become a packaging expert. At ShipBots, dunnage is included in our fulfillment services, free, recyclable, and optimized for your products. Whether you need kitting fulfillment services, fashion fulfillment, or large-scale warehouse shipping, weâve got you covered.
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