Expendable vs. Returnable Dunnage: Which Is Right for Automotive Parts?

Returnable dunnage is usually the better choice when parts move in high volume on a closed loop between a supplier and a plant, because the packaging is reused many times and the cost per trip falls well below one-way packaging. Expendable packaging is the better choice for low volume, one-way, export or unpredictable lanes where getting containers back is not practical. Many programs use both.

What is dunnage?

Dunnage is the interior packaging that holds and protects parts inside a container, such as partitions, trays, foam inserts or fabric pockets. It can be expendable (used once) or returnable (cleaned and reused).

When does returnable dunnage make sense?

• Steady, high-volume part flows on the same route.

• A closed loop where empty containers come back to the supplier.

• Parts that need consistent, rigid positioning every shipment.

• Customers with sustainability or waste reduction goals.

When is expendable packaging the better option?

• Low or irregular volume.

• One-way, export or long-distance shipments.

• Service parts and aftermarket programs.

• Launches and prototypes before the design is final.

What returnable dunnage materials are available?

Common options include plastic corrugated dividers that are rigid and cleanable, precision-sewn fabric dunnage for Class A and sensitive parts, collapsible containers such as ITB systems, and thermoformed plastic trays and inserts that cradle each part in a custom contour.

How do you start a returnable program?

Start with part drawings or samples, annual volume, the shipping route and cycle time, and the container footprint. From there, a dunnage design can be built, sampled and tested on the line before full production.

Who supplies returnable dunnage for automotive suppliers in Michigan and Ohio?

Allpacks supplies both expendable and returnable packaging for automotive and industrial manufacturers from locations in Flint and Brutus, Michigan, Clyde, Ohio and Fort Payne, Alabama, and is an authorized ITB provider. See returnable solutions or request a quote.

Frequently asked questions

What is the difference between expendable and returnable dunnage?

Expendable dunnage is used once and discarded or recycled. Returnable dunnage is built to be cleaned and reused over many shipping cycles on a closed loop.

When is returnable packaging worth it?

Returnable packaging is usually worth it for steady, high-volume part flows on a closed loop where empty containers return to the supplier.

What materials are used for returnable dunnage?

Common materials include plastic corrugated dividers, sewn fabric dunnage, collapsible containers such as ITB systems, and thermoformed plastic trays.