Q: What is dunnage in shipping? → A: Dunnage refers to protective materials like air pillows, foam inserts, and bubble wrap that secure cargo during transport — preventing up to 40% of the 85 million packages that arrived damaged in 2025.
Nearly 3-4% of all shipped packages in the U.S. arrive damaged, costing businesses over $50 billion annually in shipping damage. The term Packing material encompasses every protective material that keeps products safe during transit — from simple paper fill to advanced foam-in-place systems.
Void fill acts as your cargo’s bodyguard, absorbing shocks and preventing movement that causes damage. With global eCommerce sales projected to hit $7 trillion in 2025, effective protective filler selection has never been more critical for protecting profits and customer satisfaction. Understanding shipping policies and regulations helps ensure your cushioning strategy remains compliant while maximizing protection.
What Is it and Why Does Every Shipper Need It?
Packing material encompasses all materials used to protect, secure, and stabilize cargo during transport. Originally coined by maritime shippers who used wood and bamboo to brace cargo in ship holds, void fill now includes any protective material that prevents product damage in trucks, planes, and delivery vans.
The primary function of protective filler is threefold: absorb impact forces, prevent cargo movement, and fill voids that would otherwise allow products to shift during transit. Without proper cushioning, even routine handling can cause devastating damage to shipments.
Why is it critical for shipping success? Consider that 1 in 25 packages arrives damaged, creating a cascading effect of replacement costs, return logistics, customer service calls, and reputation damage. A single damaged shipment doesn’t just cost you the product value — it can cost up to 3x that amount when you factor in shipping costs both ways, labor, and lost customer lifetime value.
What Types of Products Need packing material Protection?
Every shipped product benefits from appropriate void fill, but certain categories require mandatory protection, and reviewing our guide to Shipping Specific Items can help you identify the right protective filler strategy for your particular product type:
- Electronics: Circuit boards, screens, and components are extremely vulnerable to shock damage
- Glass and ceramics: Even minor impacts can cause catastrophic failure
- Heavy machinery: Weight distribution and securing prevent structural damage
- Irregularly shaped items: Custom cushioning prevents pressure points and movement
- Temperature-sensitive products: Insulating it maintains product integrity
Even seemingly durable items like books or clothing benefit from void fill that prevents package compression and maintains professional presentation upon delivery.
How Does packing material Reduce Shipping Costs?
Quality void fill typically costs 2-5% of total shipping expenses but can reduce damage claims by up to 80%. Here’s the cost-benefit breakdown:
- Damage prevention: Saves 3x replacement costs per avoided da
FAQ
What exactly is protective filler in shipping?
Cushioning refers to protective materials like air pillows, foam inserts, and bubble wrap used to secure cargo during transport. It prevents the 85 million packages that arrived damaged in 2025 by absorbing impact forces and preventing movement that causes product damage.
How much should I spend on it per package?
Target packing material costs at 2-5% of total shipping expenses for standard goods, with fragile items requiring up to 8%. Quality void fill typically costs a small amount per package but prevents damage claims that can be substantial per incident.
Which protective filler materials are required for international shipping?
International shipments require ISPM 15 compliant wood cushioning that’s heat-treated and marked with accredited seals. Biodegradable materials are mandatory for EU and California shipments exceeding 1,000 units annually, with fines up to $10,000 for violations.
What is the cheapest effective it for small businesses?
Recycled air pillows offer the best cost-to-protection ratio at a very low per-use cost for void filling applications. Paper-based void fill costs slightly more per use and provides adequate protection for non-fragile items under 10 pounds.
How do I know if I’m using enough packing material?
Use 2-5% of box volume for standard goods and double that for fragiles. Products should not move when packages are shaken, and damage rates should remain below 2-3% of total shipments to indicate adequate protection levels.
Do air dunnage bags really prevent shipping damage?
Yes, properly inflated air dunnage bags reduce shipping damage by up to 80% by absorbing shock and preventing movement. They’re particularly effective for electronics and fragile items when combined with appropriate void fill materials.
What dunnage works best for drone deliveries in 2025?
Ultra-light mycelium foams designed for drone deliveries can withstand G-forces up to 10x gravity while remaining completely biodegradable. These materials meet the extreme protection requirements of automated delivery systems.
Are there AI tools to help select dunnage?
Yes, AI optimization tools analyze product data to improve dunnage material matches by up to 20%. These systems consider product weight, fragility, shipping distance, and carrier requirements to recommend optimal protection strategies.
What’s the environmental impact of different dunnage materials?
More than 5 billion pounds of returned ecommerce packages end up in landfills annually, often due to packaging damage. Biodegradable options like cornstarch peanuts and mushroom packaging reduce environmental impact while meeting 2025 compliance requirements.
How does PalletPath help with large item dunnage?
PalletPath connects shippers with LTL carriers specializing in heavy-duty dunnage for items over 150 pounds. Businesses save $170-270 per mattress shipment while receiving professional-grade protection with specialized securing equipment.
What are the new dunnage regulations for 2026?
New packaging laws require recyclable dunnage with fines up to $10,000 per violation. UPS dimensional weight rules now apply to packages exceeding 10,368 cubic inches, affecting dunnage selection for cost optimization.
Can I reuse dunnage materials to save money?
Yes, inflatable dunnage bags can be reused 50+ times if handled properly. Customer return programs for clean dunnage materials help businesses implement circular economy principles while reducing protection costs by 20-40%.
Part of our Box Cutter guide. Related: Standard Box Sizes, Shipping Supplies and Packaging, Are Bubble Mailers Considered Packages.
