If you’ve ever opened a shipping box and found crumpled brown paper packed around the product, you’ve already met dunnage paper. It’s one of the simplest tools in packaging, but it’s also one of the most misunderstood. A lot of businesses buy whatever their supplier stocks without asking whether it actually fits the product they’re shipping. That’s usually where damage claims start.
This guide breaks down what dunnage paper actually is, the types you’ll run into, and how to choose one without overspending or under-protecting your shipments.
What Is Dunnage Paper?
Dunnage paper is a paper-based cushioning material used to fill empty space inside a box and absorb shock during transit. It sits between the product and the walls of the box, stopping items from sliding around, knocking into each other, or taking the full force of a drop.
Unlike foam or plastic void fill, dunnage paper is made from kraft or recycled paper stock. That makes it recyclable, biodegradable, and generally cheaper per cubic foot than plastic alternatives — which is a big part of why it’s become the default choice for brands trying to cut down on plastic packaging.
Why Businesses Use Paper Dunnage Instead of Plastic
A few years ago, bubble wrap and foam peanuts were the standard. That’s shifted, and not just for environmental reasons:
- Cost per shipment. Paper dunnage is usually lighter and cheaper to source in bulk than plastic fill.
- Dimensional weight pricing. Carriers charge based on box size and weight, so lighter paper fill can shave real money off shipping costs at scale.
- Regulatory pressure. Several regions have restricted single-use plastics in packaging, pushing brands toward paper-based alternatives.
- Unboxing experience. Kraft paper reads as more premium and intentional than a fistful of packing peanuts, especially for direct-to-consumer brands.
- Recyclability. Customers can toss it in a normal recycling or compost bin, which plastic fill usually can’t do.
Types of Dunnage Paper
Not all paper dunnage does the same job. Here’s how the common types stack up.
| Type | Best For | Protection Level | Cost |
| Crinkle/shredded kraft paper | Light items, void fill | Light to medium | Low |
| Corrugated paper dunnage | Fragile or mid-weight items (glass, ceramics) | Medium to high | Medium |
| Honeycomb paper padding | Heavier or irregularly shaped products | High | Medium to high |
| Kraft paper sheets/rolls | Wrapping individual items | Light | Low |
Crinkle paper is shredded kraft paper, usually the cheapest and most common option for filling gaps in lightweight boxes. It’s not built for heavy shock absorption, but it works well for apparel, small goods, and general void fill.
Corrugated dunnage uses the same fluted structure as cardboard boxes — two flat liners with a wavy layer sandwiched between them. That structure gives it real cushioning strength, which is why it shows up often in glassware, electronics accessories, and anything with sharp corners that need protecting.
Honeycomb paper padding is the step up from corrugated when you’re shipping something heavier or oddly shaped. It compresses under impact and springs back, which spreads out force instead of transferring it directly to the product.
Kraft paper sheets are more about wrapping than filling — think wrapping a fragile item before it goes into the box, rather than stuffing the gaps around it.
How to Choose the Right Dunnage Paper
Before ordering in bulk, run through these questions:
- How fragile is the product? Glass, ceramics, and anything with moving parts need more structured protection like corrugated or honeycomb padding, not just crinkle paper.
- What’s the shipping distance and carrier? Longer transit times and multiple handling points mean more opportunities for impact damage.
- What’s your box-to-product size ratio? If there’s a lot of empty space, you need enough volume of paper to actually stop movement, not just a token handful.
- Does weight matter for your shipping cost? If you’re being charged on dimensional weight, paper’s lighter profile compared to foam can add up in savings.
- Is sustainability part of your brand story? If your packaging is part of your marketing, kraft paper dunnage tends to photograph and unbox better than plastic fill.
A good rule of thumb: match the paper type to the fragility of the product, not the price tag. Underpacking a fragile item to save a few cents per box usually costs more in replacements and refunds down the line.
Common Mistakes to Avoid
- Using too little paper. If the product can still move when you shake the closed box, it’s underpacked.
- Assuming crinkle paper works for everything. It’s fine for soft goods, but it won’t stop a ceramic mug from cracking on impact.
- Ignoring corner protection. Most shipping damage happens at the corners and edges of a box, not the flat sides.
- Buying loose paper without a system. Bulk rolls with a dispenser or a crinkle-cut machine save time and reduce waste compared to hand-tearing paper for every order.
