How polyurethane dunnage can save your business money
In both manufacturing and logistics, efficiency and cost savings are a crucial combination to maximise profits. One overlooked area where companies can significantly reduce expenses is in their choice of dunnage. Traditional dunnage materials like wood, foam or corrugated cardboard can be inefficient, wasteful, and costly in the long run.
Polyurethane (PU) dunnage, on the other hand, is durable, reusable and highly customisable, meaning operations can be streamlined while costs are reduced. Discover how PU dunnage can change the way you ship and store your products and ultimately save your business money.
What is polyurethane (PU) dunnage?
Polyurethane dunnage is a type of protective material used to secure and cushion products during transportation and storage. Unlike traditional dunnage which is often single-use, PU dunnage is:
- Custom-moulded to fit specific products
- Highly durable, shock absorbent and resistant to impacts
- Reusable for hundreds or even thousands of trips
- Environmentally friendly, reducing waste compared to disposable alternatives
PU dunnage is commonly used in industries such as the automotive, aerospace, electronics and heavy machinery industry, where protecting high value products in transit and storage is fundamental to maximising profits.
How PU dunnage makes shipping and storage versatile
Custom-shaped dunnage
One of the biggest advantages of PU dunnage is its ability to be precisely designed and moulded to fit the contours of specific products. This ensures:
- Tighter packing, reducing wasted space in shipping containers
- Better protection, minimising movement and potential damage
- Consistency, ensuring every unit is secured the same way
Robust & long-lasting
Unlike foam or cardboard, which degrades quickly, PU dunnage is:
- Resistant to crushing, moisture and chemicals
- Able to withstand repeated use without losing shape
- Ideal for both heavy and high-value items
Reusable
Because PU dunnage doesn’t break down easily, it can be reused which:
- Eliminates the recurring cost of disposable dunnage
- Reduces procurement and waste management/recycling issues
- Improves your businesses sustainability efforts
Sustainable
With sustainability at the forefront of most business’ minds, PU dunnage offers:
- Less material heading to landfill compared to single-use materials
- A lower carbon footprint due to a reduced need to manufacture single-use dunnage
- Contributions towards green initiatives
Why PU dunnage is particularly useful for lean manufacturing
Lean manufacturing focuses on eliminating waste in time, materials used and the movement of goods or people. PU dunnage supports this philosophy by ensuring the goods or parts transported to the production line arrive in one piece and are ready to be used straight off the truck. By ensuring no parts are damaged in transit, no extra parts are needed to be transported to the production line “just in case”, which means only the necessary parts are transported at the time they’re needed. This reduces wasted time, materials and movement of goods, the core philosophies of lean manufacturing.
What does PU dunnage have to do with the Toyota Production System (TPS)?
The Toyota Production System (TPS) is the pinnacle of lean manufacturing, emphasising just-in-time (JIT) production and continuous improvement (known as “kaizen”). PU dunnage plays a crucial role in TPS by:
- Ensuring parts arrive undamaged (reducing production line downtime, defects and rework)
- Supporting JIT logistics (reusable dunnage means no delays waiting for new materials)
- Reducing “muda” (waste) in transportation, time and storage space
Toyota and other TPS-inspired manufacturers often use custom PU dunnage to maintain efficiency and cost-effectiveness in their supply chains.
How PU dunnage reduces costs for Just-in-Time (JIT) manufacturing
Just-in-time (JIT) manufacturing relies on precise, waste-free logistics. PU dunnage enhances JIT by:
Reducing downtime
- No need to wait for replacement dunnage, just reuse existing PU inserts.
- Faster loading/unloading due to custom-fit designs.
Reducing storage costs
- PU dunnage is stackable and space-efficient, maximising container space.
- With PU dunnage ensuring parts arrive undamaged, there is no need to store large amounts of inventory (a core principle of lean manufacturing).
Reducing shipping costs
- PU dunnage is lighter than wood, which reduces overall freight weight.
- More efficient use of container space means fewer trips needed.
Reducing damage in transit
- Fewer defects mean lower return rates and warranty claims.
- Less product loss = higher profit margins.
Frequently Asked Questions
What is dunnage?
Dunnage refers to the materials used to protect and secure goods and parts during shipping and storage. Common types of dunnage include wood, cardboard, foam and plastic (usually polyurethane). PU dunnage is becoming the preferred choice for manufacturers, specifically businesses that use lean manufacturing, due to its superior protection during transit, reusability and ability to be made into bespoke shapes.
What is lean manufacturing?
Lean manufacturing is an approach to manufacturing which emphasises minimising waste and maximising efficiency. It focuses on providing more value for the customer using fewer resources.
What is Just-in-Time (JIT) manufacturing?
JIT is a strategy where materials are delivered exactly when needed to the production line, reducing inventory storage costs. PU dunnage supports JIT by ensuring reliable, reusable protection which reduce delays.
