Custom Dunnage Packaging Services
At Express Packing, we specialize in custom dunnage solutions that protect high-value, fragile, or heavy goods throughout the shipping journey. Whether you’re transporting Class-A automotive components, sensitive aerospace equipment, or industrial machinery, the right dunnage makes the difference between damage-free delivery and costly claims.
Our engineers design and fabricate dunnage systems that meet the most demanding requirements—balancing protection, compliance, cost-efficiency, and sustainability. From foam inserts to export-compliant wood blocking, we tailor each solution to your product, your process, and your logistics challenges.
What Is Dunnage Packaging?
Dunnage is the unsung hero of freight protection. It refers to the materials used to secure, separate, and protect goods during transport. By filling voids and absorbing shock, dunnage ensures that parts and assemblies arrive intact and undamaged.
Shippers select dunnage based on product fragility, weight, and transport conditions. For example:
- A glass vase may require bubble wrap to stabilize it inside a box.
- A pillow may need no additional support.
- A motor assembly might need wood blocking to prevent movement during transit.
By reducing load movement and cushioning items from vibration, dunnage lowers the risk of product loss, shipping claims, and costly replacements.
Dunnage vs. Cushioning
Although often confused, dunnage and cushioning serve different but complementary purposes.
- Dunnage includes any material that prevents product damage, provides moisture protection, and minimizes shifting.
- Cushioning specifically absorbs shock and vibration to protect fragile items.
When packaging design combines both, goods receive maximum protection:
- Dunnage fills empty spaces and locks items in place
- Cushioning absorbs impact energy and prevents cracks, dents, or breakage.
Common Dunnage Types
Shippers and packaging engineers select from a wide range of dunnage materials depending on product type, fragility, and shipping environment.
Foam
- Ideal for electronics, optics, and medical equipment. Foam-in-place or die-cut foam isolates surfaces from vibration and provides gentle support.
Corrugated or Kraft Paper
- Crumpled paper is cost-effective, recyclable, and eco-friendly, making it a popular void-fill solution.
Wood Blocking & Bracing
- Provides structural stability for heavy loads. Export shipments require ISPM-15 heat-treated and marked wood.
Air Pillows & Inflatable Bags
- Large air-filled sacks stabilize heavy machinery or pallets during transit.
Molded Pulp & Plastics
- Designed for high-value or industrial goods where precision-shaped packaging is needed.
Reusable Racks & Soft Liners
- Used in automotive and aerospace supply chains to protect painted or delicate surfaces.
Why Shippers Use Dunnage
Shippers rely on dunnage because it directly reduces costs, damages, and risks during transportation.
- Prevents cargo damage: About 25% of damage occurs during handling, while two-thirds of claims come from poor packaging. Dunnage minimizes both.
- Absorbs shock and vibration: Proper cushioning protects delicate electronics, optics, and precision machinery.
- Prevents load shifting: Void fill and blocking secure items against collisions inside containers.
- Moisture protection: Barrier materials reduce exposure to humidity and condensation during long-haul or ocean shipments.
- Protects reputation: Minimizing claims means fewer delays, warranty issues, and unhappy customers.
Our Dunnage Capabilities
Express Packing offers full-spectrum dunnage design and fabrication in our Indianapolis facility. From one-off inserts to nationwide supply chain programs, our team delivers precision-engineered solutions.
Foam Systems
- Foam-in-place cushions, die-cut polyethylene inserts, and high-density wraps for electronics, optics, and Class-A parts. Non-abrasive foams/soft liners prevent scratches on chrome or painted finishes.
Paper & Corrugated Builds
- Lightweight void fills, crinkle packs, and multi-wall corrugated builds reduce overall packaging weight and freight costs. Custom partitions ensure parts remain line-ready.
Engineered Wood Blocking & Bracing
- Dimensional lumber cut to exact size, compliant with ISPM-15 for export. Our team applies required IPPC markings to avoid costly border rejections.
Reusable Options
- HDPE racks, steel frames, and soft-lined totes designed for closed-loop programs. These protect Class-A finishes, reduce packaging waste, and create long-term cost savings.
Industries & Use Cases We Serve
Our dunnage solutions are customized for multiple industries, ensuring compliance, efficiency, and damage-free delivery.
- Manufacturing & Industrial Equipment – Pumps, motors, and CNC machines are secured with a mix of engineered bracing, cushioning foam, and vapor barriers.
- Automotive & Transportation – Assembly plants rely on reusable racks with soft liners for Class-A panels, dashboards, and trim, plus corrugated inserts for smaller parts.
- Defense & Aerospace – Packaging designed to meet MIL-STD-2073 preservation and MIL-STD-129 marking requirements. We provide full documentation and compliance reporting for sensitive equipment.
Secure packing without leaving your facility
Our mobile packing crews handle large machinery and sensitive assets on-site, reducing risks and saving time.
Compliance You Can Count On
For regulated industries, compliance is critical. Express Packing delivers dunnage solutions that not only protect goods but also meet national and international packaging standards.
- ISPM-15 Certification – All export wood dunnage must be heat-treated or fumigated and marked with the ISPM-15 stamp. Our facility is certified, and every job includes documented proof.
- MIL-STD-2073 Methods – Defense and aerospace shipments require adherence to preservation and marking codes. We apply correct codes and prepare documentation packages to ensure audit readiness.
- ASTM D4169 Testing – Our packaging can be tested to simulate real-world hazards like vibration, shock, compression, and moisture. This provides validation for high-value or sensitive shipments.
With Express Packing, you can trust that your shipments won’t be delayed or rejected due to noncompliant packaging.
Documentation & Traceability
Our quality management system ensures complete visibility into every dunnage project. Each order includes:
- Photographic records before closure
- Heat-treat stamps and certificates for wood materials
- Bills of materials and packing lists
- Optional humidity, tilt, and shock indicators for sensitive freight
- Comprehensive documentation provided for audit-ready transparency.
This level of documentation reduces risk, satisfies inspectors, and gives your quality team peace of mind.
Our Process
We follow a structured approach that guarantees consistency, compliance, and protection at every stage.
- Discovery & Site Walk – We review drawings, materials, and handling paths, often visiting your site for first-hand evaluation.
- Design & Material Selection – Using CAD modeling, we balance weight, cost, sustainability, and compliance requirements.
- Build & Kitting – In-house fabrication ensures quality. Foam is cut, wood is milled, and corrugated inserts are die-cut to exact specifications.
- On-Site Packing – Our mobile crews handle oversize or sensitive equipment directly at your location, reducing handling risks.
- Quality Assurance & Documentation – Final inspections, labeling, and compliance documentation are completed before shipment.
Reduce waste while saving money
Our reusable and recyclable packaging solutions support your environmental goals without compromising performance.
Cost, Lead Times & Logistics
Pricing and timing for custom dunnage vary based on several factors:
- Weight & Fragility – Heavy machinery requires more robust builds; fragile components often need intricate foam systems.
- Quantity & Repeatability – Large-scale runs reduce per-unit costs, while one-off builds carry higher setup charges.
- Material Selection – Specialty foams, engineered woods, and compliance requirements increase costs compared with basic corrugated designs.
- Reusability – Returnable racks and totes involve higher upfront costs but deliver long-term savings.
- Testing & Compliance – Additional ASTM testing, MIL-STD documentation, or ISPM-15 stamping extend lead times.
Typical Lead Times:
- Lead times vary by scope.
- Rush services available for critical outages or line-down scenarios
Our Indianapolis location allows us to serve the Midwest daily, with national deployment available for large projects.
Sustainability Options
We engineer dunnage solutions that balance performance with environmental responsibility.
- Reusable Dunnage Loops – Returnable totes, racks, and inserts reduce single-use packaging and landfill waste.
- Recyclable Materials – Kraft paper and corrugated builds are fully recyclable and often made with recycled content.
- Right-Sizing Designs – Optimizing packaging dimensions lowers material use and shipping emissions.
- Responsible Wood Sourcing – Export projects use ISPM-15 heat-treated, debarked wood to meet ISPM-15 requirements. Alternatives such as plywood and strand board are considered when suitable.
By integrating sustainability into packaging design, we help customers cut waste, lower long-term costs, and support corporate environmental goals.
Frequently Asked Questions
What’s the difference between dunnage and cushioning?
Dunnage secures and stabilizes products with materials like foam, paper, air pillows, wood, or plastics. Cushioning absorbs vibration and shock. Both are often combined for maximum protection.
Can you provide ISPM-15-marked wood dunnage?
Yes. Our facility is certified, and every export shipment includes traceable stamps and certificates, ensuring compliance with USDA regulations.
Do you offer on-site packing?
Yes. Our mobile teams travel with tools, foam systems, and equipment to pack large or sensitive assets at your location. This minimizes handling and reduces risk.
Do you support MIL-STD projects?
Absolutely. We prepare packaging that complies with MIL-STD-2073-1; marking per contract (e.g., 129 when specified). Full documentation and requirement codes are included for defense contracts.
Protect Your Shipments with Express Packing
The right dunnage solution prevents costly damage, delays, and claims. Express Packing engineers design packaging that meets technical, regulatory, and budget requirements across industries.
Whether you need:
- Foam inserts for Class-A automotive parts
- Engineered wood blocking for industrial equipment
- Reusable systems for closed-loop logistics
We have the experience and compliance credentials to deliver.
Don’t risk damage or costly claims
Our experts design packaging that protects your products, ensures compliance, and keeps your operations running smoothly.