Manufacturers in automotive, aerospace, medical, and electronics industries depend on safe, reliable methods for transporting and storing delicate components. When parts are exposed to unnecessary movement, impact, or abrasion, the cost of damage can escalate quickly. This is where custom dunnage inserts become an essential part of an efficient material handling system. Designed to fit your parts exactly, these inserts help eliminate shifting, prevent contamination, and ensure consistency throughout your workflow.
Salco Engineering and Manufacturing specializes in designing and producing custom dunnage systems that support clean, organized, and damage-free transport. Whether you need a single prototype or a full fleet of inserts for your production line, Salco’s precision-engineered solutions help protect your inventory from the moment it leaves the workstation to its final destination.
Precision Craftsmanship for High-Value Components
Custom dunnage inserts offer benefits that generic dividers and foam blocks cannot match. Each insert we build is engineered around your exact part dimensions, geometry, weight, and handling requirements. This ensures that every component sits securely in place, reducing the risk of abrasion, denting, or impact during transport.
Our design team uses advanced CAD modeling and prototyping methods to verify fit and function before production begins. These capabilities align with the same engineering principles we apply to other solutions such as custom dunnage systems and precision wire baskets, ensuring consistency across your material handling workflow.
Understanding Returnable Plastic Dunnage
Many industries use returnable plastic totes as part of their day-to-day operations. These reusable containers reduce packaging waste, improve organization, and lower long-term shipping costs. Salco enhances these totes by adding custom inserts or wire dunnage frames that securely hold parts in place.
Returnable plastic dunnage offers several advantages:
- Reduced packaging waste and lower material costs
- Stackability for more efficient storage and transport
- Lighter weight compared to metal containers
- Improved protection when combined with custom wire inserts
By combining lightweight totes with durable steel wire dividers, Salco delivers a hybrid solution that balances strength, efficiency, and part protection.
Key Benefits of Custom Dunnage Inserts
Enhanced Protection
The primary function of custom dunnage inserts is to protect your parts. Because each insert is designed around the exact shape of your product, every component remains stable throughout movement. This prevents contact between parts, reduces the risk of surface defects, and ensures consistent quality from process to process.
Improved Production and Logistics Efficiency
Custom dunnage supports lean manufacturing by creating standardized, repeatable workflows. With parts positioned consistently every time, operators can load, unload, and inspect components more quickly.
This efficiency aligns well with other streamlined handling solutions such as in-process material handling equipment and industrial trolley carts, which further reduce downtime and improve throughput.
Better Organization and Inventory Control
A well-designed dunnage insert helps maintain order within your facility. Each part has a designated space, which improves visual management and reduces the risk of misplacement. Organized totes also support quality inspections and ensure that the correct number of parts are present during each stage of manufacturing and shipping.
Materials and Design Options
Salco offers a variety of materials, wire structures, and design features depending on your handling requirements. Options include:
- Steel wire frames for added strength and longevity
- Plastic or composite inserts for lightweight applications
- Welded wire forms designed for tight tolerances
- Removable or stackable configurations
Our team uses advanced design and prototyping capabilities—similar to the processes outlined in our design and prototyping services—to create inserts that match your parts with precision.
Why Manufacturers Choose Salco for Custom Dunnage Inserts
With over six decades of experience in industrial fabrication, Salco Engineering delivers dunnage solutions that hold up under demanding production environments. Our combination of engineering expertise, in-house fabrication, and rapid prototyping ensures:
- Accurate, repeatable designs built around your exact part geometry
- Durable materials that withstand long-term industrial use
- Fast turnaround for prototypes and full production orders
- Integration with existing totes, racks, or custom carts
We also support complex projects involving multiple part families, staged processes, or specialized handling requirements.
Protect Your Parts with Precision-Engineered Dunnage
Custom dunnage inserts are an essential investment for manufacturers that prioritize quality, safety, and production efficiency. By eliminating unnecessary movement and protecting parts throughout their journey, these inserts help reduce defects, control costs, and maintain consistency across the supply chain.
If you’re ready to improve your part protection and streamline your workflow, contact Salco Engineering today. Our team will work closely with you to design a custom dunnage solution that fits your parts, your processes, and your long-term operational goals.