Product Description-Fabricated

Interiors and dunnage refer to the inner packaging of a 
reusable container.

Fabricated foam interiors range from simple die cut holds in pads to intricate 
water-jet cut, close tolerance components.  Sheet materials can be cut to create custom dividers to separate parts from each other in the same container.  Many 
interiors are a combination of several materials (i.e. foam base pad, plastic 
corrugated dividers laminated with non-woven roll material).

Protective interiors protect parts in three basic ways:

1)  Protect parts from hitting one another (separates, braces and blocks parts).

2)  Protect parts from shock and vibration (cushioning of sensitive parts).

3)  Protect delicate surfaces and paints (non-abrasive materials to avoid scratching).


 
Key  Features


--Most interiors are custom designed to cover exact individual protection needs.

--Tooling costs are generally affordable for small to medium sized dunnage set 
  requirements.

--Some standard divider sets and base pads available.

--Many foam options are available (urethanes, polyethylene, cross-linked 
  polyethylene) depending on part requirements.

--Many sheet materials available (solid polyethylene, 2mm to 10mm thickness 
  plastic corrugated).

--Dunnage can be designed in some cases to collapse for use with knockdown 
  containers.

--Interiors can be used with small hand held containers up to large bulk containers 
  and rack systems.

 

Issues to Consider



--Selecting the correct materials for your product protection needs (shock/vibration, 
  scratching, shattering and cracking).

--Tooling costs:  generally low to medium range (i.e. estimated $50 to $5,000).

--Reviewing part orientation for maximum space utilization.

--Cleaning of dunnage based on part type (oily, dusty,painted) and shipping 
  conditions.

--Fastening of interiors to containers (Velcro, rivets) if required (containers inverted 
  when empty or washed together).

--Designing interiors with raw material (foams planks/buns and plastic corrugated 
  sheets) sizes in mind (generally multiples of 12", 24" and 48").

Product Description-Thermoformed

                                

Interiors and dunnage refer to the inner packaging of a reusable container.

Vacuum formed dunnage refers to a rigid tray or pad formed by drawing a heated 
sheet material (typically polyethylene or polystyrene, 1/16" to 1/4" thickness) over a molding die.  The heated and supple sheet material is drawn into the mold cavities 
by a strong downward vacuum force.

Trays can also be formed of crossed-linked polyethylene foams (XLPE) to form rigid, non-abrasive trays and layer pads.

Layered pallet packs refer to shipping stacked, layered and palletized products.   Individual layers are sets of rigid plastic dividers or stacked components.

Protective interiors protect parts in three basic ways:

1)  Protect parts from hitting one another (separates, braces and blocks parts).

2)  Protect parts from shock and vibration (cushioning sensitive parts).

3)  Protect delicate surfaces and paints (soft materials to avoid scratching).
Key Features
 
--Completely customized dunnage to suit the products protection needs.

--Good for heavy parts that require bracing and blocking.

--Good for greasy or oily parts, dunnage can be cleaned with high pressure or hot 
  water scrubbing.

--Best for large quantities of interior requirements:  many exact specification parts 
  can be produced without a large amount of labor and assembly.

--Creates a clean, well designed, professional looking pack.
Issues to Consider
 
--Tooling costs:  generally medium to high cost (i.e. estimated $5,000 to $15,000) 
  typically require larger quantities to justify tooling costs.

--Cleaning of dunnage based on part type (oily, dusty, painted) and shipping 
  conditions.

--Fastening of interiors to containers (Velcro, rivets) if required (containers inverted 
  when empty or washed together).
 
 



©Copyright 1998-2006  Returnable Packaging Network Corporation
Terms & Conditions for Access & Use of Returnables.com

The information contained herein is believed to be reliable, but no representations, guarantees 
or warranties of any kind are made as to its accuracy, suitability for particular applications or the 
results to be obtained therefrom.  No warranties or guarantees are made as to suitability of the 
products for the application disclosed.  Full-scale testing and end product performance are the 
responsibility of the user.  Returnables.com shall not be liable for and the customer assumes all 
risk and liability of any use or handling of any material beyond Returnables.com's direct control.  Returnables.com MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED 
TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR 
PURPOSE.  Nothing contained herein is to be considered as permission, recommendation, nor 
as an inducement to practice any patented invention without permission of the patent owner.
 

I