Your shipping department faces a daily challenge: protecting products during transit without breaking your budget or disappointing environmentally conscious customers.
Traditional packaging materials like bubble wrap and foam peanuts work, but they’re expensive, non-recyclable, and increasingly unpopular with customers who prioritize sustainability.
Paper dunnage is a protective packaging material made from kraft paper or recycled paper that cushions products and fills voids in shipping boxes. Unlike plastic alternatives, it’s biodegradable, recyclable through curbside programs, and often costs less per package.
Why the shift to paper matters:
- Customer demand – Consumers actively seek sustainable packaging options
- Regulatory pressure – New laws are phasing out single-use plastics
- Better performance – Modern paper dunnage matches plastic protection capabilities
Understanding dunnage basics
Dunnage refers to protective dunnage materials used to secure cargo and prevent damage during shipping. Every package faces rough handling, vibrations, and impacts as it moves through sorting facilities, trucks, and delivery vehicles. Without proper dunnage protection, even sturdy products arrive damaged, leading to costly returns and disappointed customers.
The shipping industry relies on various types of dunnage to protect goods during the shipping process. From traditional packing peanuts and bubble wrap to modern air pillows and corrugated paper solutions, understanding the different types of dunnage available helps businesses choose the right dunnage for their specific needs. Professional third-party logistics providers have extensive experience selecting optimal dunnage materials based on product characteristics, shipping methods, and customer requirements.
Why paper dunnage is gaining momentum
Traditional packaging materials like bubble wrap and foam peanuts are falling out of favor for several reasons:
Consumer demand for sustainability drives purchasing decisions. Many consumers are willing to pay more for sustainable packaging materials, making eco-friendly paper dunnage a competitive advantage over conventional packing materials.
Regulatory pressure in various regions limits single-use plastics. The European Union’s Single-Use Plastics Directive and California’s SB 54 specifically target plastic packaging reduction, making paper dunnage alternatives essential for compliance.
Improved manufacturing techniques have enhanced paper dunnage’s protective capabilities, making it competitive with plastic air pillows and bubble wrap options while maintaining environmental benefits and cost advantages.
Key benefits of paper dunnage
Superior protection at lower cost
Paper dunnage provides excellent shock absorption and prevents product movement during transit. The natural cushioning properties of paper fibers distribute impact forces across broader areas, reducing damage from drops and vibrations. This makes paper dunnage ideal for protecting fragile items during shipping.
Unlike rigid dunnage materials or solid plastics, paper dunnage conforms to product shapes while filling empty spaces effectively. This flexibility allows it to protect delicate items and sensitive items equally well.
NOTE: Paper weight (measured in GSM) varies based on application requirements, with different weights suitable for light, medium, and heavy items.
Environmental advantages that customers notice
Paper dunnage delivers significant environmental benefits that support your sustainability goals:
Curbside recyclable through standard municipal programs available to most U.S. consumers
Biodegradable within weeks, unlike plastic materials that persist for decades
FSC-certified options ensure responsible forest management and transparent supply chains
Eco-friendly alternative to traditional packing peanuts and bubble wrap
Made from recycled paper options maximize environmental benefits
Cost advantages over plastic alternatives
Paper dunnage typically costs less than plastic alternatives while reducing package weight, resulting in lower shipping costs through dimensional weight pricing. The cost-effective nature of paper dunnage makes it attractive for businesses looking to reduce both packaging materials expenses and shipping costs.
Types and formats of paper dunnage
Common dunnage materials in paper form
Kraft paper dunnage represents the most common variety, made from virgin wood pulp using the kraft process. This manufacturing method produces strong, durable kraft paper with excellent tear resistance and cushioning properties for protecting goods during transit.
Recycled paper dunnage offers even greater sustainability, manufactured from post-consumer waste paper. While slightly less strong than virgin kraft paper, recycled paper varieties provide adequate protection for most products while maximizing environmental benefits.
Corrugated paper solutions offer engineered protection for heavy items and heavy cargo. These corrugated paper materials feature fluted construction that provides exceptional strength while maintaining the eco-friendly characteristics of paper-based dunnage materials.
Standard paper dunnage formats
Kraft paper rolls and pads provide versatile protection options. Large rolls can be cut to size as needed, while pre-cut pads offer convenience for standardized operations. Pads are available in various sizes to accommodate different packaging requirements.
Crinkle paper and void fill represents the most popular format. This paper dunnage material features a pleated structure that creates air pockets for excellent cushioning while maintaining an attractive appearance. Void fill machines can produce custom crinkle paper on demand, minimizing waste while ensuring proper dunnage protection.
Shredded cardboard provides an excellent alternative to packing peanuts for void fill applications. This shredded cardboard material offers superior cushioning compared to traditional foam padding while being completely recyclable. Shredded cardboard works particularly well for lightweight and small packages, providing cost-effective protection.
Honeycomb paper offers exceptional strength-to-weight ratios for heavy cargo applications. Unlike standard corrugated paper, honeycomb structures provide enhanced crush resistance for protecting high-value items during shipping.
When paper dunnage works best (and when it doesn’t)
Ideal applications
Paper dunnage excels for:
Most ecommerce fulfillment operations requiring void fill protection
Electronics and fragile items requiring breathable protection
Products where sustainable packaging materials add brand value
International shipping (exempt from ISPM-15 wood treatment requirements)
Small packages and lightweight products that don’t require heavy-duty protection
Component packs and kit assembly requiring organized protection
Important limitations to consider
Certain applications require alternative dunnage materials:
WARNING: Extreme moisture environments can compromise paper dunnage’s protective capabilities. Products exposed to high humidity or potential water contact may need plastic air pillows or other moisture protection solutions.
Very heavy items may require more robust protection than standard paper dunnage provides. Dense machinery or steel components typically need solid foam dunnage or wood dunnage for adequate damage protection. For businesses regularly shipping big and heavy products, specialized fulfillment solutions often provide better protection than standard paper dunnage options.
Sharp or jagged products with the potential to puncture packaging materials aren’t suitable for paper dunnage applications. These items may require bubble wrap or specialized protective packaging materials.
Medical equipment shipments often require sterile packaging conditions that paper dunnage cannot provide, necessitating specialized dunnage materials designed for healthcare applications.
How to calculate paper dunnage requirements
Determining the optimal amount requires careful calculation of void space and protection needs:
01
Calculate package volume (Length × Width × Height)
02
Calculate product volume using similar measurements
03
Subtract product volume from package volume for void space
04
Apply a fill factor for the specific dunnage material based on product requirements
05
Convert to weight using paper density specifications
PRO TIP: Work with your supplier to determine the appropriate dunnage options based on your cardboard boxes’ dimensions, product weight, and protection requirements. Different types of dunnage require varying amounts to achieve proper protection.
Implementation guide for fulfillment operations
Manual vs automated systems
Manual application works well for smaller operations processing moderate package volumes daily. Team members can easily adjust paper dunnage quantities based on specific requirements while maintaining cost control. This approach works particularly well when shipping products of varying sizes to different destinations.
Automated paper-void machines offer advantages for high-volume operations. These systems produce consistent quantities on demand, reducing labor costs while eliminating waste. Investment costs vary significantly based on features and capacity, with most operations seeing positive ROI over time.
Professional 3PL services often utilize sophisticated packaging systems that can accommodate both manual and automated dunnage application, allowing businesses to scale their protective packaging strategies as order volumes grow.
Cost optimization strategies
Right-sizing packages represents an effective cost-saving strategy. Using the appropriate box size reduces the need for excessive void fill while lowering dimensional weight shipping costs. Package optimization can significantly reduce paper dunnage usage across all shipping products.
Volume contracts with suppliers yield savings through committed purchases and long-term partnerships. Many suppliers offer progressive pricing tiers that reward consistent volume levels and provide better rates on various materials.
Floor dunnage considerations for warehouse operations can also impact costs. Proper storage of paper dunnage materials on wood pallets or appropriate shelving helps maintain quality while reducing waste.
Comparing paper dunnage to alternatives
Paper dunnage vs bubble wrap
While bubble wrap provides excellent shock absorption, paper dunnage offers comparable protection for most applications. Like bubble wrap, paper dunnage conforms to product shapes, but paper dunnage provides superior environmental benefits and often lower costs per package.
Paper dunnage vs air pillows
Air pillows excel at filling large void spaces quickly, but paper dunnage offers more versatile protection. Unlike air pillows, paper dunnage won’t deflate if punctured and provides better surface protection for products with sharp edges.
Paper dunnage vs packing peanuts
Traditional packing peanuts create static and disposal problems that paper dunnage eliminates. Paper dunnage provides similar void fill capabilities while being completely recyclable and biodegradable, making it the environmentally friendly choice.
Custom dunnage solutions
For specialized applications, custom dunnage solutions may combine paper dunnage with other materials. These hybrid approaches can optimize protection while maintaining sustainability goals, particularly for high-value items or complex shipping requirements.
Sustainability and compliance considerations
Paper dunnage offers significant compliance advantages for modern businesses seeking eco-friendly dunnage solutions:
FSC certification provides third-party verification of sustainable sourcing practices, helping meet corporate sustainability commitments while providing marketing advantages with environmentally conscious consumers.
ISPM-15 exemption simplifies international shipping logistics. Unlike wood blocks or wood pallets, paper dunnage doesn’t require treatment or special documentation, potentially saving significant costs per international shipment.
Regional compliance varies significantly. European markets often have strict regulations favoring environmentally friendly packaging materials, while U.S. state regulations like California’s SB 54 require packaging materials to be recyclable or compostable by 2032.
The essential component of sustainable packaging strategies includes choosing dunnage materials that support customer satisfaction while meeting environmental regulations. Paper dunnage serves as an ideal solution for businesses transitioning away from traditional plastic-based protection methods.
Frequently asked questions
How strong is kraft paper dunnage compared to bubble wrap?
Properly selected kraft paper provides comparable protection to bubble wrap for most ecommerce applications, with added benefits of recyclability and biodegradability. The specific dunnage material chosen should match your product’s protection requirements.
What paper weight should I choose for different products?
Paper weight requirements vary based on product characteristics. Light items need lower GSM paper, while heavy items require higher GSM options. Consult with your supplier to determine the appropriate specifications for your specific products.
Can paper dunnage replace air pillows?
Yes, crinkle paper and honeycomb formats provide similar cushioning properties to air pillows while offering superior environmental benefits and often lower costs. Paper dunnage also won’t deflate like punctured air pillows.
How much does paper dunnage cost per package?
Costs vary significantly based on package size, paper weight, volume levels, and supplier relationships. Paper dunnage typically costs less than plastic alternatives while providing comparable protection and supporting sustainability goals.
Is shredded cardboard as effective as packing peanuts?
Shredded cardboard provides excellent cushioning comparable to packing peanuts while being completely recyclable. It works particularly well as void fill material for transporting lightweight items and offers better environmental benefits than traditional foam alternatives.
What dunnage options work best for heavy cargo?
Heavy cargo typically requires corrugated paper solutions or honeycomb paper materials that provide enhanced structural support. These solid dunnage materials offer the strength needed while maintaining the eco-friendly characteristics of paper-based solutions.
