Dunnage

	Custom Interiors and Dunnage
	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").
	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).

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