What Are Custom Dunnage Inserts?
Dunnage inserts are internal structures used to support, separate, position, and protect individual components within a container, tote, rack, or other material handling system. Rather than allowing parts to move loosely inside a container, custom dunnage creates designated locations designed around each component’s size, shape, weight, and surface requirements.
Industrial dunnage can take many forms, including formed-wire frames, dividers, cradles, locating features, and other part-holding structures. The appropriate configuration depends on how the components are manufactured, handled, stored, and transported.
For manufacturers moving precision parts between machining, washing, inspection, assembly, and shipping operations, custom dunnage inserts can provide a consistent handling method throughout the production process. Parts remain organized in predictable positions, making it easier for employees to load, unload, count, and inspect components.
Salco specializes in custom steel wire dunnage inserts that combine structural strength with an open, relatively lightweight design. These inserts can be manufactured to fit standard returnable totes or other application-specific containers.
Custom Wire Inserts for Returnable Plastic Totes
Returnable plastic totes are commonly used in automotive manufacturing, aerospace production, industrial warehousing, and other operations where components travel repeatedly between facilities or workstations. These containers offer practical advantages for storage and transportation, but a standard empty tote may not provide adequate protection for sensitive parts.
Salco enhances returnable packaging systems with custom wire inserts designed to fit securely inside the selected container. Formed steel wire frames and dividers create individual part locations while allowing the outer tote to provide containment and support for the overall packaging system.
Each insert can be designed around the interior dimensions of the container, the number of components being transported, and the amount of clearance needed between individual parts.
Steel Wire Dividers and Part Separators
Custom wire dividers create defined spaces within a plastic tote, helping prevent components from contacting one another during normal handling and transportation. Divider spacing can be designed around individual parts, allowing manufacturers to establish consistent loading patterns and quantities per container.
For components with irregular shapes, wire separators can incorporate bends, offsets, or other formed features that support the part at appropriate locations.
Custom-Fitted Wire Frames
Wire frames can be designed to fit within an existing container while supporting multiple dividers or part-holding elements. The frame provides a foundation for the insert and can be reinforced where additional load support is required.
Depending on the application, an insert may be designed for removal from the tote or for use as part of a more permanent container configuration. The design should also account for how workers access the parts and whether the empty container must nest or stack during return transportation.
Part-Holding Cradles and Locating Features
Some components require more than simple separation. Parts with complex geometry, precision surfaces, or uneven weight distribution may need dedicated support points that maintain their orientation during handling.
Salco can manufacture formed-wire structures with custom bends, supports, and locating features designed around these requirements. The objective is to support each component securely while maintaining clearance around surfaces that should not contact the insert.
Advantages of Steel Wire Dunnage Inserts
Steel wire inserts provide a versatile alternative to fully molded interior packaging, particularly when manufacturers need strong, durable part-holding structures that can be customized for specific components.
Reliable Part Separation and Protection
Custom wire dunnage can help reduce part-to-part contact and limit unwanted movement within a container. This is especially valuable for machined components, finished metal parts, and assemblies with surfaces that must remain protected during transportation.
When additional surface protection is necessary, the wire structure can be designed to accommodate suitable protective contact materials or finishing options.
Durability for Repeated Industrial Use
Fabricated steel wire provides strength and structural stability for inserts that must withstand repeated loading, unloading, and transportation. Properly designed wire frames and welded connections can provide dependable support over multiple handling cycles.
Efficient Container Weight
Open wire construction allows support to be placed where needed without filling the entire container with solid material. This can help control the weight of the dunnage system while maintaining the structural features required for the application.
Flexible Customization
Custom wire inserts can be manufactured with different divider arrangements, frame dimensions, support locations, and part-holding configurations. This flexibility makes wire dunnage useful for manufacturers handling specialized components or developing packaging around existing reusable containers.
Reduced Dependence on Disposable Packaging
Returnable dunnage systems can reduce recurring purchases of disposable packaging when containers circulate through an established return process. Reusable wire inserts can also support long-term packaging standardization and make it easier to maintain consistent handling procedures across production and shipping operations.
The long-term value depends on factors such as container reuse frequency, return transportation, maintenance, and the expected life of the packaging system.
Custom Dunnage Design Considerations
An effective dunnage insert must do more than fit inside a plastic tote. It should protect the parts while supporting practical loading, unloading, transportation, storage, and production requirements.
Part Dimensions and Geometry
Each insert begins with the dimensions and geometry of the components being handled. Overall length, width, height, weight, and part shape influence the arrangement of dividers and support features.
Unusual geometries may require specially formed wire supports, while more uniform components may be efficiently arranged in repeating compartments.
Weight Capacity and Structural Support
The total weight of the components determines how the wire frame and supporting members should be constructed. Heavier parts may require larger wire diameters, reinforced framing, additional contact points, or other structural features.
Load distribution is particularly important when several heavy components share one container. Both the insert and the outer tote must be suitable for the combined weight.
Part Orientation and Surface Protection
Precision components often contain critical machined surfaces, locating features, or finished areas that should not contact other parts or hard support surfaces.
Custom dunnage allows those contact requirements to be incorporated into the design. Parts can be positioned to maintain clearance where needed while resting against appropriate support locations.
Container Dimensions and Stackability
Wire inserts must fit within the usable interior dimensions of the selected container without interfering with stacking features, handles, lids, or other container components.
For returnable packaging programs, empty-container storage and return transportation may also influence the insert design. Maintaining compatibility with the existing tote system can help manufacturers avoid unnecessary changes to established logistics procedures.
Loading, Unloading, and Automation
Operator access is another important consideration. Components should be positioned so employees can load and remove them without unnecessary reaching, twisting, or interference from surrounding wire features.
For automated production systems, consistent part orientation and locating features may help support robotic loading and unloading. These applications require additional consideration of equipment clearances, gripping points, and positional repeatability.
Materials and Finish Options for Custom Dunnage
Material selection depends on the weight and type of components being handled, the operating environment, and the required level of surface protection. Salco manufactures custom wire products using carbon steel and stainless steel, with finishing options considered according to the application.
Carbon Steel Wire Inserts
Carbon steel provides strength and durability for many general-purpose manufacturing and material handling applications. It is commonly suitable for reusable inserts used in controlled industrial environments and can be combined with protective finishes when additional corrosion resistance is necessary.
Stainless Steel Wire Inserts
Stainless steel may be preferred when corrosion resistance, cleanliness, or repeated exposure to moisture is important. Stainless steel wire inserts can also be useful in manufacturing environments where the packaging system must tolerate regular cleaning.
Protective Coatings and Contact Materials
Depending on the application, powder coating, nylon coating, plating, or other surface treatments may be considered. Protective finishes can help address corrosion concerns or reduce direct metal contact with sensitive components.
For parts requiring additional cushioning, a wire dunnage design may also incorporate suitable polymer or protective contact materials where needed. The correct combination depends on the part surface, operating environment, cleaning procedures, and expected wear.
Custom Dunnage Inserts for Automotive and Aerospace Manufacturing
Automotive and aerospace manufacturers often handle components with complex geometries, finished surfaces, and demanding transportation requirements. Custom dunnage inserts help establish repeatable loading arrangements while keeping parts organized as they move between suppliers, production facilities, inspection departments, and assembly operations.
Automotive Components
Automotive suppliers may need returnable dunnage for machined housings, transmission components, steering assemblies, brackets, and other parts that require separation during manufacturing or shipment. Custom wire inserts can be configured around the number of components per tote and the way those parts are handled at each stage of production.
For operations using reusable packaging across established supplier routes, properly designed inserts can support a more consistent material flow while reducing dependence on disposable separators.
Aerospace Parts
Aerospace components may require careful positioning because of their value, irregular geometry, or sensitive machined surfaces. Custom wire supports can maintain clearance around critical features while providing stable positioning within a reusable container.
The material, contact surfaces, and construction should be selected according to the component and any applicable cleanliness or handling requirements.
Medical, Electronics, and Industrial Equipment
Custom dunnage can also be useful for medical equipment components, electronic assemblies, precision metal parts, and machinery components. In these applications, organized storage and consistent part positioning can help reduce unnecessary handling while supporting efficient inventory and production operations.
Integrating Dunnage Inserts With Existing Material Handling Systems
Custom dunnage inserts are most effective when designed as part of the larger manufacturing and logistics process. A tote may need to move from receiving to storage, machining, inspection, assembly, and shipping without repeated transfers of its contents.
Salco’s custom wire baskets provide additional options for applications that require a complete fabricated steel container rather than an insert for a plastic tote. For operations moving multiple containers between departments, industrial carts and trolleys can also be designed around the dimensions and handling requirements of existing containers.
Coordinating these products helps manufacturers establish more consistent material handling processes, improve workstation organization, and reduce unnecessary movement between different storage and transportation methods.
Custom Engineering, Wire Forming, and Prototyping
Salco Engineering approaches custom dunnage development by understanding the components, container configuration, and operating requirements before determining the final insert design.
Our design and prototyping capabilities include SolidWorks CAD modeling and physical prototyping, allowing customers to evaluate part fit, access, structural features, and overall configuration before repeat production.
For custom wire inserts, Salco can utilize its CNC wire forming capabilities to produce repeatable wire shapes, dividers, and supporting components. These formed parts can then be incorporated into fabricated and welded dunnage assemblies.
This combination of design, CNC wire forming, and custom fabrication provides flexibility for both straightforward divider systems and more complicated inserts requiring multiple bends, precise component positioning, or specialized support structures.
What Information Is Needed for a Custom Dunnage Quote?
Providing detailed project information helps Salco evaluate the appropriate insert construction and develop an accurate quotation. While a completed engineering drawing is helpful, customers can also begin by sharing part samples, container information, or a description of the intended application.
Useful information includes:
- Part dimensions, drawings, or photographs
- Individual component weight and total weight per container
- Number of parts required in each tote or container
- Existing container dimensions and specifications
- Critical surfaces that must be protected from contact
- Preferred material and protective finish
- Expected handling, shipping, and storage conditions
- Manual or automated loading requirements
- Estimated quantity of inserts needed
- Any existing packaging problems the new design should address
These details allow our team to assess design requirements, identify potential constraints, and determine whether an existing concept can be adapted or a completely new insert configuration is required.
Frequently Asked Questions About Custom Dunnage Inserts
Can Salco Design Wire Inserts for Existing Plastic Totes?
Yes. Custom wire inserts can be engineered around the interior dimensions of an existing plastic tote or returnable container. Providing the container specifications or a physical sample helps ensure proper fit and compatibility with the intended loading and stacking requirements.
Are Custom Dunnage Inserts Reusable?
Steel wire dunnage inserts are designed for repeated industrial handling when properly engineered for the application. Their expected service life depends on load weight, frequency of use, operating conditions, and maintenance. Reusable inserts are particularly useful for manufacturing operations with established returnable packaging programs.
Can Wire Dunnage Protect Delicate or Finished Parts?
Yes. Custom dividers and formed-wire supports can be designed to keep sensitive components separated and positioned away from critical contact areas. Depending on the part surface, protective coatings or additional contact materials may also be incorporated into the design.
Can Salco Manufacture Custom Dunnage Inserts From a Drawing or Sample?
Salco can work with customer drawings, part samples, container specifications, and application requirements to develop custom dunnage configurations. CAD modeling and prototyping can help evaluate fit and function before moving into production.
Why Choose Salco Engineering for Custom Dunnage Inserts?
Salco Engineering & Manufacturing brings more than 60 years of experience in custom steel fabrication and industrial material handling products. Our expertise includes wire forming, welded assemblies, custom wire baskets, dunnage inserts, carts, and other products developed around specific manufacturing needs.
Rather than relying on a one-size-fits-all packaging approach, Salco works with manufacturers to develop wire dunnage that addresses the dimensions, support requirements, handling conditions, and operational challenges of the components being transported.
Our in-house design and fabrication capabilities allow customers to work with a manufacturing partner that understands both the individual wire components and the complete assembled product. Whether you need inserts for an existing plastic tote, a new returnable packaging configuration, or a specialized part-holding solution, Salco can help develop a practical design.
Request a Quote for Custom Dunnage Inserts
Custom dunnage inserts can improve part protection, organization, and handling efficiency throughout manufacturing and logistics operations. By combining durable steel wire construction with application-specific design, manufacturers can create reusable packaging solutions that support their components and existing workflows.
Salco Engineering manufactures custom wire dunnage inserts, dividers, and part-holding structures for automotive, aerospace, medical, electronics, and industrial manufacturing applications. Our team can review your parts, container dimensions, material requirements, and production needs to develop a solution suited to your operation.
Request a custom dunnage insert quote to get started, or contact Salco Engineering to discuss your project with our team.
