Custom Returnable / Reusable Packaging

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  • HDPE Dunnage for Stamped Aluminum Part
    HDPE Dunnage for Stamped Aluminum Part
  • PCORR/Foam Dunnage for HVAC Control
    PCORR/Foam Dunnage for HVAC Control
  • PCORR/Foam Dunnage for Navigation Unit
    PCORR/Foam Dunnage for Navigation Unit
  • PCORR/Foam Dunnage for Heavy Equipment Part
    PCORR/Foam Dunnage for Heavy Equipment Part
  • PCORR/Foam Dunnage for Motorcycle Shifter
    PCORR/Foam Dunnage for Motorcycle Shifter

Interior Packaging Design, LLC provides customers with innovative custom reusable packaging solutions. These solutions not only help customers improve the quality of in-process shipping, but over the life of the packaging, it can save costs over disposable dunnage. Packaging types include totes, pallets, top caps, pads, sleeve packs, and tethered lids. Dunnage engineers work with customers to determine the correct foam, rubber, or plastic material to fit their application. Depending on the design and volume, materials can be die cut or water jet cut to custom fit components. Custom solutions decrease part damage and streamline shipping. Not only does custom reusable packaging upgrade the quality of the shipping system, it can pay for itself quickly when considering the continually rising cost of corrugated cardboard and other disposable dunnage options.

Our 4 head, 3-axis water jet cutting machine is capable of cutting up to 1,000 inches per minute. We can cut material up to 10’ x 12’ and 5” thick to produce custom shaped containers, dunnage, pads, and trays. Packaging can also be coated in Class A laminate, brushed fabric, or Spuntex. In addition to reusable packaging, we can create expendable packaging solutions for applications when reusable packaging is not a viable option. Samples can be produced very quickly, often within a few days. Our response time and customer service is unmatched in the industry, with full scale production runs typically taking only four weeks. Dimensional and material testing can be performed to ensure that all packaging meets customer specifications. Custom labeling or bar coding are also available and we can make repairs to any damaged packaging. For more information about custom returnable/reusable packaging design and manufacturing capabilities, see the table below, or contact us directly.

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Custom Returnable/Reusable Packaging Capabilities

General CapabilitiesDunnage Engineering
Reusable Packaging
Returnable Packaging
Packaging TypesTotes
Pallets
Topcaps
Divider Sets
Foam Pads
Boxes
Containers
Teathered Lids
ProcessDie Cutting
Flatbed Rolling
Water Jet Cutting
Slicing
Skiving Heat Source
Ultrasonic Welding
Gluing
Assembly
Water Jet Cutting Machine3 Axis
4 Head
Redundant Pumps
110,000 psi
1,000 in/min
Edge Quality1 to 5
Material FormCorrugated
Open Cell
Closed Cell
Cross Linked
MaterialsPolyethylene
Urethane
HDPE
LDPE
Delrin
Composites
Rubber
Foam
Plastic
Plexiglas
FinishesClass A Laminate
Brushed Fabric
Spuntex
Cutting ThicknessUp to 5 in
Cutting LengthUp to 12 ft
Cutting WidthUp to 10 ft
Tolerance± 1/8 in (Die Cut)
± 1/16 in (Foam)
± 1/64 in (Water Jet)
InspectionDimensional
TestingMaterialLaminate
Quality ControlManual
Additional ServicesDesign
Bar Coding
Labeling
Bulk Container Repair
Production VolumePrototype to Production
Lead Time2 days (Conception to First Sample)4 weeks (Typical)
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Additional Information

Industry FocusAerospace
Agricultural
Automotive
Chemical
Electronic
Heavy Equipment
Injection Molding
Medical
Pharmaceutical
Components PackagedRadios
Navigation Units
Fuel Lines
Wheels
Battery Trays
Motorcycle Assembly
File FormatsSolidWorks
AutoCAD
STEP
IGES
DXF
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