Custom Corrugated Plastic Dunnage
Reusable Protective Dunnage for Automotive and Industrial Parts
Custom corrugated plastic dunnage is designed to hold, separate and protect automotive and industrial components during handling, storage and return transport. The protective system is developed around part geometry, contact points, loading direction, pack density and integration with the outer box or tote.
- Part location and approved contact areas
- Custom layouts for repeated loading
- Integration with existing boxes or totes
Corrugated Plastic Dunnage for Part Protection
Dunnage brings the protective elements inside a container together as one coordinated system. Its purpose is to locate each component, maintain separation and limit unwanted movement while keeping loading and removal practical. Contact surfaces and access for the operator are considered alongside the number of parts in each pack.
A system may combine partitions, inserts, layer pads, support panels or custom cut components made from PP corrugated plastic. Each element has a specific role; a project does not need every structure. The layout should support the part without creating unnecessary contact or obstructing removal.
Designed Around the Part and Handling Process
Part Geometry & Contact Points
Dimensions, shape and weight establish the starting layout. Identify sensitive surfaces, approved support areas and the preferred loading orientation. Clearance around each component should allow operators to place and lift it without forcing it into position. Pack density is reviewed together with access, rather than maximizing the part count alone. For the full decision sequence, see our automotive dunnage design guide.
Handling & Return Route
Describe manual loading, warehouse movement, internal transfers and any export transport. For closed-loop routes, include how empty packaging returns and how often it is loaded and unloaded. These details inform the structure and inspection requirements. Reuse suitability depends on the actual load, handling conditions and condition of the packaging.
Dunnage Structures and Custom Options
Cell partitions and slotted dividers can establish separation, while die-cut inserts and layer pads organize the component positions and loading sequence. Cut support panels can be considered where the approved contact layout requires them. Custom dimensions allow these elements to fit the usable internal space of the container.
Printing and identification can help distinguish part references or loading positions. Material thickness and GSM are selected according to the part, layout and handling requirements. The proposed corrugated polypropylene structure should be reviewed against the component and outer packaging before specifications are approved.
Automotive & Industrial Applications
Automotive parts dunnage can support organized presentation of components for assembly-line handling, work-in-process storage and returnable transport. Mechanical and metal parts may need defined support points and clearance between surfaces. For sensitive electronic components, any additional protection requirements must be confirmed during project review.
For broader route and container planning, see our industrial and automotive packaging applications. This product page focuses on the protective layout inside that packaging system.
Dunnage, Dividers and Outer Packaging
Dunnage is the complete protective and locating system. Corrugated plastic dividers and inserts are individual separation components that may form part of it. The outer container provides the external handling and transport enclosure.
Our corrugated plastic boxes and reusable bins and totes can be considered alongside the internal layout. If the container is already specified, share its usable dimensions and access restrictions so the dunnage and container can be reviewed together.
What We Need for a Dunnage Project
Send the available information below for a focused project review. Photos help explain handling, while drawings identify dimensions and contact restrictions.
- Part dimensions, drawings or photos, and unit weight
- Quantity per container and preferred loading direction
- Sensitive surfaces and permitted contact areas
- Outer box or tote dimensions, if already defined
- Handling route, loading frequency and return conditions
- Estimated order quantity and any identification requirements
Frequently Asked Questions
What is corrugated plastic dunnage?
It is a custom protective system made from corrugated polypropylene, also called PP hollow board, that locates and separates parts within a handling container.
Can the dunnage be designed around an existing box or tote?
Yes. Provide the usable internal dimensions, opening, loading direction and any container features that restrict the layout.
Can dividers and inserts be integrated into the dunnage?
Yes. They can be combined with other cut components where the part geometry and approved contact areas require them.
What information is needed to design custom dunnage?
Start with a drawing or photos, part dimensions and weight, pack quantity, contact restrictions, container details and handling route.
Get a Quote for Custom Dunnage
Share your component and packaging requirements so we can review a suitable protective layout for your operation.