The Ultimate Guide to Dunnage: How to Protect Your Products in UK Shipping

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.

Paper Dunnage

Paper dunnage is one of the most common options. It is crumpled or folded to fill space and provide light cushioning.

Benefits:

• Recyclable and biodegradable

• Affordable and lightweight

• Versatile for many product types

Best for:

• Clothing

• Books

• Beauty products

• Small household items

  
  

Air Pillows

Air pillows offer void fill without significant weight. They form a lightweight barrier that absorbs impact.

Benefits:

• Very lightweight

• Good for filling larger gaps

• Reusable

Best for:

• Home goods

• Packaged electronics

• Cosmetics

  
  

Bubble Wrap

Bubble wrap provides direct cushioning for fragile goods.

Benefits:

• Protects against shocks

• Wraps around irregular shapes

• Reusable

Best for:

• Glassware

• Electronics

• Ceramics

  
  

Foam Inserts

Foam dunnage is often custom moulded to the product shape.

Benefits:

• Precise fit

• Excellent shock absorption

• Suitable for high value items

Best for:

• Technical equipment

• Medical devices

• Tools and instruments

  
  

Corrugated Cardboard Inserts

Corrugated board can be cut, folded, and layered to separate and secure items.

Benefits:

• Fully recyclable

• Strong and lightweight

• Customisable

Best for:

• Food products

• Homeware

• Appliances

  
  

Wooden Dunnage

Wood is used for large or heavy industrial items.

Benefits:

• Very strong

• Reusable

• Supports heavy loads

Best for:

• Furniture

• Machinery

• Oversized items

  
  

Inflatable Dunnage Bags

Inflatable dunnage is typically used for bulk shipments and pallet loads.

Benefits:

• Saves space prior to inflation

• Secures entire loads

• Prevents shifting in containers

Best for:

• 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.

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.