The Ultimate Guide to Dunnage: How to Protect Your Products in UK Shipping
- Blue30
- Dec 15, 2025
- 6 min read
Updated: Jan 3
Most online sellers focus on product quality, courier partners, or packaging design, but far fewer think about the protective materials inside the box. Yet this simple element, known as dunnage, is often the deciding factor between a flawless delivery and a costly customer complaint.
Whether you sell fragile homeware, premium electronics, or lightweight fashion items, the right dunnage ensures your products survive the bumps, pressure, and unpredictable handling that take place throughout the shipping journey.
At Blue30 Fulfilment, we know that great packaging goes beyond the box itself. That is why we include free dunnage as part of our standard pick and pack fees. Our team carefully selects the correct protective material for every order, ensuring maximum safety without increasing parcel weight unnecessarily. This prevents inflated courier charges and helps you keep control of your fulfilment costs.
In this guide, we explore what dunnage is, the different types available, why it matters for e-commerce, and how Blue30 uses smart dunnage techniques to safeguard your products and strengthen your brand reputation.
This comprehensive guide explains what dunnage is, why it matters, the types available, how to choose the right option, and how Blue30 applies best practices to safeguard your products. If you sell online and want fewer damaged parcels, happier customers, and more efficient operations, this is the guide you need.
What Is Dunnage in E-commerce Fulfilment?
Dunnage refers to any material placed inside a parcel or shipping container to protect the product from damage during transit. It can be simple, such as crumpled paper, or highly engineered, like custom foam inserts. Regardless of the form it takes, its purpose is always the same: preventing items from shifting, absorbing impact, and keeping products stable during handling and delivery.
Examples of common dunnage include:
Paper fillers
Crinkle paper
Bubble wrap
Air pillows
Corrugated cardboard inserts
Foam sheets or moulded foam
Inflatable dunnage bags
Dunnage is not just used for fragile goods. Even robust items require protection, especially when shipped with other products in multi-item orders.
Why Dunnage Matters More Than Most Sellers Realise
Dunnage may seem like a small detail, but it has a direct impact on your customer satisfaction levels, return rates, warehouse efficiency, and profit margins. Without proper dunnage, products slide, collide, or absorb shock during transportation, leading to cracked packaging, scuffed products, internal component damage, or even total breakages.
Here is why dunnage is essential:
Reduces product movement
Void space is one of the biggest causes of shipping damage. Dunnage fills those gaps to prevent sliding and impact.
Absorbs shock and vibration
Transport involves constant motion, including handling at sorting hubs, conveyor systems, vehicle movement, air turbulence, and manual loading. Dunnage keeps products cushioned.
Protects against moisture
Some dunnage materials shield products from humidity, dampness, or minor leaks during transit.
Improves customer experience
When parcels arrive damaged, customers lose confidence in your brand. Dunnage prevents this and helps maintain excellent review ratings.
Reduces returns and replacement costs
Every return is expensive. Proper dunnage dramatically reduces the number of damaged goods returned.
Supports sustainability goals
Eco friendly dunnage options help reduce landfill waste and improve brand reputation.
At Blue30, we carefully select the correct dunnage for each SKU to ensure every product is properly protected while keeping material usage efficient and environmentally responsible.
The Main Benefits of Using Dunnage in Fulfilment
Fulfilment centres and ecommerce brands benefit from dunnage in several important ways.
Helps save money on damage-related costs
The more your products are protected, the fewer returns you face. Returns eat into profits through replacement stock, reshipping costs, and labour time.
Reduces shipping expenses
While dunnage provides protection, using the wrong material can increase parcel weight. Blue30 avoids this by selecting lightweight yet protective materials that keep courier fees competitive.
Improves packing speed and consistency
With a standardised dunnage process, packers can work faster and deliver consistent results.
Boosts customer satisfaction
Safe deliveries lead to five star reviews, repeat orders, and brand loyalty.
Protects your reputation on marketplaces
If you sell on Amazon UK, eBay, Shopify, Etsy, TikTok Shop or other platforms, damage complaints affect performance metrics. Good dunnage protects your accounts.
Types of Dunnage Used in UK E-commerce Fulfilment
Different products require different protective materials. Here are the main types used in fulfilment operations across the UK.
Dunnage Type | Benefits | Best For |
Paper Dunnage | - Recyclable and biodegradable - Affordable and lightweight - Versatile for many product types | - Clothing - Books - Beauty products - Small household items |
Air Pillows | - Very lightweight - Good for filling larger gaps - Reusable | - Home goods - Packaged electronics - Cosmetics |
Bubble Wrap | - Protects against shocks - Wraps around irregular shapes - Reusable | - Glassware - Electronics - Ceramics |
Foam Inserts | - Precise fit - Excellent shock absorption - Suitable for high value items | - Technical equipment - Medical devices - Tools and instruments |
Corrugated Cardboard Inserts | - Fully recyclable - Strong and lightweight - Customisable | - Food products - Homeware - Appliances |
Wooden Dunnage | - Very strong - Reusable - Supports heavy loads | - Furniture - Machinery - Oversized items |
Inflatable Dunnage Bags | - Saves space prior to inflation - Secures entire loads - Prevents shifting in containers | - Palletised goods - International shipping |
Choosing the Right Dunnage for Your Products
Selecting the right dunnage is vital to protect goods while keeping costs under control. Here is what ecommerce brands should consider.
Product weight and fragility
Lightweight items may only require paper, while fragile goods need cushioning such as bubble wrap or foam.
Shipping method
Air freight charges by weight, making lightweight dunnage ideal. Long road or sea journeys may require sturdier protection.
Packaging size
Oversized boxes lead to excessive dunnage use. Choosing the correct box reduces the need for extra materials.
Environmental considerations
Many UK brands now prioritise recyclable and compostable packaging.
Overall cost
The goal is reliable protection with minimal material usage.
At Blue30, we evaluate all these factors to ensure your products receive the best protection without unnecessary weight or added costs.
Supplier | What They Offer | Indicative Pricing | URL / Notes |
Magna Packaging UK | Packaging & protective materials (likely stock dunnage bags/paper on request) | Quote on request | |
Woods Packaging Ltd | Packaging supplies incl. cushioning materials | Quote on request | |
Woodlands Timber Packaging Ltd | Timber dunnage / protective wood packaging | Quote on request | |
Zeus Packaging (UK) Ltd | Broad packaging range, potentially including void‑fill/dunnage | Quote on request | |
Danda UK Packaging | Packaging supplier with cushioning products | Quote on request | |
Manupackaging UK Ltd | Packing materials & void fill options | Quote on request |
The Environmental Impact of Dunnage
Not all dunnage is equal in terms of sustainability. The ecommerce sector produces millions of tonnes of packaging waste every year. Choosing eco friendly dunnage options helps businesses reduce their carbon footprint.
Sustainable options include:
Recyclable paper fillers
Corrugated cardboard inserts
Biodegradable air pillows
Recycled foam materials
Blue30 encourages sustainable packaging solutions and uses recyclable or biodegradable dunnage wherever possible.
Best Practices for Dunnage Use in Fulfilment Centres
Fulfilment centres use best practice methods to ensure consistent and cost effective product protection.
Use the correct combination of materials
Mixing multiple types often provides stronger protection, such as paper with bubble wrap.
Fill all voids
Even small empty spaces can cause damage.
Place dunnage strategically
High impact areas such as corners require more cushioning.
Train packers thoroughly
Consistent training ensures every parcel receives the correct level of protection.
Use dunnage machines for efficiency
On demand air pillow or paper dunnage machines speed up packing and reduce waste.
Reuse materials wherever possible
Many dunnage types can be used multiple times.
Blue30 integrates all of these best practices into our daily operations.
The Future of Dunnage in UK E-commerce
As ecommerce continues to grow, so does the need for reliable packaging solutions. Innovations in dunnage are improving sustainability, automation, and efficiency.
Eco friendly materials
Expect to see more cornstarch based fillers, recycled paper, compostable air pillows, and moulded pulp inserts.
Smart automation
Some fulfilment centres now use automated dunnage dispensers and packaging scanners that calculate the exact amount of dunnage needed.
Customised dunnage
On demand moulded pulp or foam inserts designed specifically for individual products.
Smart packaging
Dunnage with embedded sensors could track shock, temperature, or handling conditions.
Blue30 actively monitors these innovations to continuously improve our fulfilment service.
Why Blue30 Fulfilment Is the Best Choice for Dunnage and Packing Quality
At Blue30 Fulfilment, we take product protection seriously. Our pick and pack service includes free dunnage, ensuring excellent protection without adding costs to your business. We always select the most suitable material for each product, balancing protection with the need to keep parcel weights low. This helps prevent inflated courier fees and keeps your logistics budget under control.
Our packing team is fully trained in efficient, sustainable, and professional dunnage application. Whether you ship fragile glassware, luxury goods, toys, electronics, or everyday consumer items, we ensure every order leaves our warehouse ready to arrive in perfect condition.
Final Thoughts
Dunnage may be small, but it has a big impact on product safety, customer satisfaction, and fulfilment efficiency. Using the right materials protects your goods, reduces returns, and keeps costs under control.
At Blue30 Fulfilment, we include free dunnage with every pick and pack order, ensuring your products arrive in perfect condition without adding extra weight or expense. Let us help you deliver safely, efficiently, and sustainably.
If you’re ready to upgrade your fulfilment quality and reduce shipping-related headaches, Blue30 is here to help. Reach out today to discover how our expert packing and dunnage processes can support your growth and elevate your customer experience.
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