In industries where precision components and high-value parts are constantly on the move, the smallest damage during transport can lead to costly delays and product loss. That’s where custom dunnage solutions make the difference. Designed to safeguard delicate or complex parts during storage and shipping, these specialized systems provide structure, stability, and protection throughout every stage of the supply chain.
At Salco Engineering & Manufacturing, our team designs and fabricates custom dunnage inserts and support systems that integrate seamlessly with baskets, racks, and material handling equipment—ensuring components stay secure and undamaged during transport.
What Is Custom Dunnage?
Dunnage refers to the protective materials or structures used to keep parts stationary and safe while being transported or stored. In industrial environments, custom dunnage systems are engineered specifically for the shape, size, and handling requirements of each part. They act as cushions or separators that prevent parts from shifting, colliding, or scratching one another during movement.
Unlike off-the-shelf dividers or foam inserts, custom-designed dunnage is tailored to fit your product perfectly. The goal is to create a repeatable and secure fit that minimizes vibration, impact, and abrasion. Whether you’re shipping automotive components, medical devices, or precision-machined assemblies, custom dunnage helps ensure every part arrives in flawless condition.
Why Dunnage Systems Matter in Modern Manufacturing
As production and logistics systems become more automated and complex, maintaining product integrity has never been more important. Dunnage systems are integral to that reliability—protecting sensitive parts through every stage of material handling, from assembly lines to final delivery.
For manufacturers that rely on just-in-time delivery or handle delicate, high-value components, effective part protection is essential. Even minor cosmetic damage can lead to rejected parts or rework, both of which disrupt production schedules and add unnecessary costs. A well-engineered dunnage system eliminates those risks by providing structured, repeatable support throughout each movement cycle.
Key Benefits of Custom Dunnage Systems
1. Superior Part Protection
Every dunnage system Salco produces is designed to protect specific part geometries, coatings, and surfaces. Whether the part has sharp edges, polished finishes, or complex contours, custom dunnage eliminates contact points that cause scratching, bending, or denting. This precision-fit approach guarantees consistent protection from manufacturing to assembly to final delivery.
2. Improved Handling Efficiency
Beyond protection, custom carts and racks equipped with dunnage inserts make handling faster and safer. Operators can quickly load and unload parts without complex packaging, reducing labor time and improving productivity. In automated facilities, consistent part positioning also supports robotic handling systems and vision-guided assembly lines.
3. Reusability and Long-Term Value
Custom dunnage systems are typically built from durable materials such as high-density polyethylene (HDPE), urethane, or steel. Unlike disposable packaging, these solutions can be reused across hundreds—or even thousands—of cycles, dramatically reducing waste and replacement costs. Over time, reusable dunnage delivers a stronger return on investment while supporting sustainability goals.
4. Compatibility with Existing Material Handling Equipment
Salco’s design team ensures that custom dunnage systems integrate seamlessly with existing steel baskets, fabricated racks, and storage containers. Each insert or support structure is tailored for your workflow—whether you need stackable, nestable, or modular designs for flexible handling and storage.
Types of Custom Dunnage Inserts and Materials
Because no two parts are identical, there’s no one-size-fits-all solution for part protection. Custom dunnage systems are built using a range of materials and designs, including:
- Plastic and Polymer Inserts: Lightweight and durable options ideal for high-volume production and easy cleaning.
- Foam or Urethane Dunnage: Offers soft cushioning for sensitive surfaces such as painted or polished parts.
- Metal Frames or Grids: Provides rigidity and structure for heavy or irregularly shaped components.
- Textile or Vinyl Covers: Adds a non-abrasive protective layer for delicate finishes or sensitive coatings.
At Salco, we combine these materials strategically to deliver a perfect balance of strength, weight, and protection. Each solution is tested for durability and designed for the exact transportation environment—whether it’s a high-vibration shipping route or a climate-controlled warehouse.
Applications Across Industries
Custom dunnage plays a vital role in industries that demand precision, cleanliness, and reliability. Common applications include:
- Automotive Manufacturing: Protecting painted panels, engine components, or interior trim during shipping and assembly.
- Aerospace: Securing complex aluminum and titanium components that require precision alignment.
- Medical Devices: Keeping sensitive instruments and implants free from contamination and physical damage.
- Electronics: Preventing electrostatic discharge (ESD) and mechanical shock for circuit boards and sensors.
- General Industrial Manufacturing: Supporting bulk handling of machined or coated parts between workstations.
In every industry, the primary goal remains the same—ensure part protection through every touchpoint in the production and logistics chain.
Designing a Custom Dunnage Solution with Salco Engineering
Developing the right dunnage system starts with understanding your components and workflow. At Salco, our design process includes a detailed assessment of part geometry, handling methods, and environmental exposure. Using CAD modeling and 3D prototyping, we create inserts and support systems that fit your specific parts with exact precision.
We also take into account the full lifecycle of your materials—designing for ease of cleaning, stackability, and integration with your existing material handling systems. Whether you need a one-time prototype or full production run, our goal is to build durable, repeatable protection that enhances your operation’s efficiency and product quality.
Safeguard Your Components with Custom Dunnage
For manufacturers, distributors, and logistics providers, protecting parts in transit isn’t optional—it’s a necessity. Investing in custom dunnage reduces product damage, minimizes downtime, and ensures that precision components reach their destination exactly as intended.
Salco Engineering & Manufacturing specializes in designing and fabricating high-quality dunnage systems and dunnage inserts for automotive, aerospace, medical, and industrial applications. With decades of experience in custom steel fabrication and material handling design, we deliver protective solutions that perform under pressure—cycle after cycle.
Ready to improve your part protection strategy? Contact Salco Engineering today to discuss a custom dunnage solution designed around your products, your process, and your performance standards.