Pallet Dunnage

Keeping Loads in Place During Movement

Goods shift. It’s almost inevitable. A forklift accelerates, the pallet tilts slightly, and goods positioned on top slide toward the edge. During transport, road surface vibration causes creeping movement that compounds over kilometres. In cold storage, moisture and temperature cycles loosen the grip between loads. These movements aren’t dramatic—you might not notice them day-to-day—but over time they add up to goods arriving damaged, staff spending extra time repositioning loads, and the quiet realisation that your packing method isn’t delivering the security you expected.

We’ve supported warehouse and logistics teams across Australia and New Zealand long enough to recognise that this problem isn’t solved by hoping goods stay put. It’s solved with the right pallet dunnage. High-friction dunnage creates a mechanical lock between load levels, preventing the slip and creep that happens when pallets rest directly on each other. It’s a straightforward material engineering solution, but one that makes a genuine difference in operation reliability and safety.

Our team at Ferrier Industrial manufactures and supplies pallet dunnage specifically engineered for this purpose. We design it to suit different load types, storage environments, and handling intensities. This guide explains how dunnage works, how to choose the right material for your operation, and how to integrate it into your warehouse and transport systems so goods stay exactly where you put them.

Background: Load Movement and Why Friction Matters

Most warehouse operations don’t start with load movement as a planning concern. Goods go on a pallet, another pallet goes on top, and theoretically that stack holds together. The reality is messier. Load movement happens in stages, and understanding those stages helps you plan an effective response.

Initial creep occurs during handling. When a loaded pallet sits on another pallet—both with smooth or worn surfaces—there’s minimal friction between them. A forklift approaching the stack, the slight acceleration as it lifts, or even vibration from nearby machinery creates lateral forces. Those forces cause the top load to shift millimetres at a time. One shift during pick-up, another during movement across the warehouse, a third when the pallet is set down. After a few handling cycles, the goods have moved enough to be noticeably off-centre.

Transport vibration compounds this during longer moves. A pallet loaded onto a truck bed vibrates at road speeds. The vibration is rhythmic and persistent. Unlike the sudden forces of forklift handling, transport vibration works steadily. Goods want to settle into the path of least resistance, which usually means toward the lower side of a tilted load or toward the rear of a moving truck. That settling isn’t a single dramatic shift—it’s persistent micromotion that, over a journey of an hour or more, results in material load repositioning.

Environmental factors add another layer. Temperature changes cause wood to expand and contract. Moisture from a warehouse floor seeping upward softens wooden surfaces. In cold storage, condensation on pallet surfaces reduces grip. These conditions don’t prevent movement—they actively encourage it by lowering the friction coefficient between surfaces.

The traditional response to load movement has been reactive. Goods arrive damaged, so next time you add restraint straps. Damage happens again, and you add more straps. But restraint straps work best as a final control—they prevent catastrophic failure, but they don’t address the underlying movement causing the problem. Preventing movement in the first place requires friction.

Friction coefficient—the measure of grip between two surfaces—sits at the centre of this problem. When two wood surfaces rest on each other, the friction coefficient is typically around 0.30 to 0.40. That’s low enough that even gentle handling forces cause shift. Add a vulcanised rubber layer, and the coefficient jumps to above 0.60. That’s the difference between goods that move and goods that stay put.

Dunnage Materials and Solutions: Creating Friction by Design

At Ferrier Industrial, we manufacture pallet dunnage from laminated veneer lumber (LVL) bonded with vulcanised rubber lining. This combination creates both structural support and high-friction grip. Understanding why this works helps you make smarter decisions about where dunnage fits in your operation.

LVL itself is engineered wood—thin veneers of timber layered and compressed to create a strong, consistent beam. It’s not solid timber, so it doesn’t warp or check the way traditional timber can. LVL beams maintain their shape through temperature and humidity changes, which means the dunnage surface stays level and true year after year. This consistency is genuinely important. If your dunnage warps or twists, it creates unstable contact points, and friction becomes unreliable.

Vulcanised rubber lining is the working surface. This isn’t generic rubber sheet—it’s engineered to provide high friction and resist abrasion. The rubber is bonded to the LVL beam with adhesive that holds through the stresses of loading, unloading, and environmental changes. We source the rubber to a friction specification: a coefficient of greater than 0.60 when tested against wood and standard pallet materials. That specification matters because it ensures consistent performance across different load types and environmental conditions.

Material grades vary by application. We supply packing-grade dunnage for single-use applications, engineering-grade for repeated handling, and boiling-water-resistant (BWR) waterproof grade for demanding environments—cold storage, outdoor storage, or applications where moisture exposure is heavy. The grade you choose depends on how long the dunnage needs to remain in service and what environmental stresses it faces.

Dimensions come in several standard options, each engineered to match common pallet widths and spacing intervals. We offer 50 × 100 mm, 75 × 75 mm, and 90 × 100 mm cross-sections in lengths ranging from 1,200 to 1,450 mm. These dimensions sit on pallet stringers or deck boards without overhang and provide adequate bearing surface to distribute load evenly. Custom dimensions are available for non-standard applications.

The engineering behind pallet dunnage isn’t complex, but it’s precise. Every dimension, every material choice, and every specification reflects operational realities we’ve observed across logistics networks and warehouses. Dunnage that’s too thin sags under load. Dunnage that’s too short doesn’t provide adequate bearing. Friction that’s too low defeats the purpose. We’ve built those lessons into standard offerings that work reliably across most operations.

Pallet Dunnage Specifications and Material Options

LVL beams with vulcanised rubber lining (50 × 100 mm, 75 × 75 mm, 90 × 100 mm cross-sections) engineered to friction coefficient above 0.60 for high slip-resistance across wood and pallet surfaces
Material grades from packing-grade to BWR waterproof suited to single-use applications, high-cycle warehouses, and harsh environmental exposure including cold storage and outdoor stacking
Standard lengths matched to pallet widths (1,200–1,450 mm) providing full-span bearing without overhang and even load distribution across pallet stringers or deck boards
Custom dimensions available for non-standard load geometries, specialised storage systems, and engineered racking applications requiring precise spacing control

How Load Movement Occurs During Handling and Transport

The mechanics of load movement become clearer when you observe them in action. Watch a forklift pick up a loaded pallet. The moment the forks engage, there’s a subtle tilt—the load leans back toward the counterweight. That tilt creates a lateral force on any pallets stacked on top. Without friction, they shift. With high-friction dunnage between levels, they don’t.

The same dynamic plays out during movement across the warehouse. A forklift turning while carrying a load creates centrifugal force. Goods want to move outward. If the pallet surface lacks grip, they do. In facilities with tight aisles or frequent turns, this becomes a noticeable issue. Goods arrive at their destination off-centre or tilted.

Transport introduces a different set of forces. A truck accelerating from a loading dock applies backward force on everything inside. As speed increases and then decreases, that force reverses. Road surface irregularities add vertical jolts. Turns apply lateral force. Together, these forces create an environment where goods naturally want to move. A pallet stacked with high-friction dunnage resists all of these forces simultaneously.

We’ve also observed how dunnage placement affects load integrity during dynamic handling. When dunnage is positioned correctly—perpendicular to pallet stringers, spaced at regular intervals—it creates a stable base for the next pallet tier. When placement is casual or inconsistent, the stability varies. Some pallets sit secure; others shift. This inconsistency is a hidden problem because it’s not immediately obvious. The load looks stable, but it’s not.

Environmental variability matters too. A warehouse with concrete floors experiences moisture transmission—water absorbed by the concrete rises through capillary action, dampening the pallet surface. This moisture reduces friction. We recommend dunnage in these environments more strongly than in climate-controlled facilities. The dunnage cost is insurance against load movement in challenging conditions.

Integration: Dunnage as Part of Your Load Restraint System

Pallet dunnage doesn’t work in isolation. It sits within a broader system of how loads are positioned, handled, and transported. Effective integration means thinking about dunnage alongside pallet selection, load configuration, and handling practices.

Pallet quality influences how well dunnage performs. A warped pallet doesn’t provide a level surface for dunnage to sit on. If dunnage rests on uneven pallet stringers, one end bears more load than the other, and friction becomes inconsistent. High-quality engineered pallets provide the flat, stable platform that makes dunnage effective. We recommend pairing dunnage selection with pallet selection—they work best together.

Dunnage placement requires consistency. We’ve seen operations where some dunnage is placed carefully perpendicular to stringers, and other layers are placed at angles or not perpendicular. That inconsistency undermines the whole system. We typically recommend two-point or three-point placement: two beams positioned at the pallet ends, or three beams with an additional centre beam for wider loads. The pattern should be consistent across your operation. Many facilities benefit from simple visual guides showing correct placement.

Load geometry affects how much dunnage you need and where. A rectangular pallet load sitting squarely on the pallet needs standard two-point dunnage. A load that overhangs the pallet, or one with an irregular shape, requires different spacing or extra support. We’ve custom-designed dunnage layouts for loads like coils, large reels, or non-standard containers where standard placement wouldn’t provide adequate support.

Handling practices determine whether dunnage benefits are realised. If your operation involves frequent restacking, where pallets are lifted and reset, dunnage consistency matters even more. Each handling cycle is an opportunity for shift if dunnage isn’t in place or correctly positioned. Training staff on dunnage importance—why it’s there, what happens without it—improves compliance and outcomes.

Transport scenarios shape dunnage selection. If goods are moving from warehouse to truck and staying there, standard engineering-grade dunnage works well. If goods are being frequently transferred between vehicles, or if they’re entering cold-chain transport, we recommend higher-grade materials. The durability investment pays for itself through fewer load failures.

Practical Decision Points: Choosing Dunnage for Your Operation

Making the shift to systematic pallet dunnage use requires a few key decisions. These aren’t complex, but they’re worth getting right.

First: What are your load types? Light, stable loads on rigid pallets might function adequately without dunnage. Medium-weight or irregular loads, or operations with frequent handling, need dunnage. Heavy loads—anything approaching maximum pallet capacity—need it. If you’re stacking pallets more than two or three levels high, dunnage becomes essential. If goods are moving frequently, dunnage is insurance.

Second: What’s your storage environment? Dry, climate-controlled warehouses with low handling intensity might operate on packing-grade dunnage. Outdoor storage, cold storage, or facilities with moisture issues need waterproof or engineering-grade material. Temperature swings, humidity, and floor moisture all argue for higher-grade material that resists environmental stress.

Third: What’s your handling intensity? Low-intensity operations—goods stored and retrieved occasionally—can use lighter dunnage. High-intensity operations—goods moving multiple times daily, frequent restacking, loads transferred between vehicles—need durable, reliable material that performs consistently. Engineering-grade dunnage with consistent rubber lining specifications is the safer choice.

Fourth: What’s your transport scenario? If goods stay in the warehouse, local handling rules apply. If goods move to trucks, freight centres, or retail distribution, transport stability matters enormously. We recommend higher-specification dunnage for any operation involving road or rail transport. The cost premium is small compared to the cost of damaged goods or failed deliveries.

Key Considerations When Specifying Pallet Dunnage

Load weight and stacking height — heavier loads and taller stacks require engineering-grade dunnage with consistent friction performance, while lighter single-level loads may function with packing-grade material
Environmental conditions and storage duration — warehouse moisture, cold storage exposure, outdoor elements, and temperature variation all favour higher-grade materials with moisture resistance and stable durability
Handling intensity and transport frequency — operations with frequent picking, restacking, or vehicle transfers benefit from reliable friction and consistent material performance that resists wear
Pallet condition and interface compatibility — flat, level pallet surfaces support consistent dunnage contact, while warped pallets or non-standard pallet widths may require custom solutions or additional placement points

How We Approach Pallet Dunnage for Your Facility

When we work with teams on pallet dunnage solutions, we don’t assume a one-size-fits-all answer. Different operations have genuinely different needs, and we’ve learned to ask the right questions early.

We begin with a discovery conversation. What loads are you handling? How heavy, how stable, how regularly do they move? What’s your storage environment—warehouse condition, temperature control, floor type? What’s your equipment—pallet dimensions, handling methods, transport distances? Are you managing any current stability issues?

From there, we assess whether dunnage is the right intervention. Sometimes it is. Sometimes the real problem is pallet quality, load configuration, or handling practices. We’re honest about this because implementing the right solution saves time and money compared to deploying dunnage that addresses only part of the problem.

At Ferrier Industrial, we manufacture dunnage in-house across our Auckland and NSW facilities, which gives us flexibility to respond to custom specifications. We also maintain stock of standard dimensions, so you’re not waiting months for supply. For operations with ongoing dunnage needs, we work through consignment and JIT arrangements—we hold inventory at or near your facility, and you only consume what you use.

We also support implementation. We can provide training to your team on dunnage placement and best practices. We develop simple visual guides for correct positioning. And we maintain spares relationships so if your operation evolves or grows, dunnage supply keeps pace.

Quality assurance matters to us too. Every dunnage beam we supply is tested for friction performance and material consistency. We work to specifications developed with partners like BlueScope Steel and NZ Steel—demanding customers with rigorous testing protocols. Those standards are built into everything we produce.

Implementing Pallet Dunnage: A Practical Roadmap

Rolling out dunnage across your operation doesn’t need to be disruptive. A staged approach works well.

Start with assessment. Spend a week observing your current operation. Which loads experience visible shift during handling? Which stacks show signs of goods creeping? Which storage areas have moisture or environmental challenges? This observation tells you where dunnage impact will be highest.

Pilot in a high-impact area. Choose one section of your operation—perhaps a specific product line, storage zone, or transport route—and implement dunnage systematically. Track results. Do goods shift less? Do loads arrive more consistently? Do staff report easier handling? That data builds confidence for wider rollout.

Establish placement standards. Work with your team to define how dunnage is positioned. Two-point placement? Three-point? Perpendicular to stringers? Specific spacing intervals? Write it down, create simple diagrams, and train staff. Consistency matters more than perfection.

Plan for continuity. As dunnage ages and wears, you’ll need replacements. Set up a routine inspection schedule—monthly or quarterly—to assess condition and order replacements proactively. Work with your supplier on consignment or regular delivery arrangements so you’re never short.

Monitor and refine. After a few months of dunnage use, revisit your original problem areas. Has load movement decreased? Are goods arriving in better condition? Are handling incidents reduced? Use that feedback to refine your approach—adjust dunnage grade, change placement patterns, or expand to new areas if results are positive.

Practical Steps for Dunnage Implementation

Conduct a site assessment — observe and document which loads show creep or movement, which storage areas have environmental challenges (moisture, temperature fluctuation), and which handling scenarios involve frequent movement or transport
Pilot dunnage in a single high-impact zone — implement standard placement patterns in one warehouse section or product line, monitor load stability and goods condition for two to four weeks, then assess whether results justify wider deployment
Establish placement and maintenance standards — create simple visual guides showing correct dunnage positioning, define inspection intervals for wear and settling, and establish processes for routine replacement of worn material
Set up supply continuity — arrange consignment or regular delivery schedules with your dunnage supplier so replacement material is always available and prevents disruption from stockouts or lead times

Support and Partnership: Beyond the Product

We see pallet dunnage as part of a bigger conversation about load stability and operational reliability. Our relationship with customers extends beyond delivery. We ask how your operation is performing months or years down the track. We listen to feedback about dunnage effectiveness. And we adjust our recommendations based on what we learn.

We’ve observed over years supporting postal networks, logistics hubs, and heavy industry operations that the best dunnage solutions come from teams that stay curious. You notice a particular load type behaves differently. You observe that cold storage creates different friction challenges than ambient temperature. You discover that a particular pallet width needs adjusted dunnage placement. Those observations, shared with your supplier, improve the entire system.

At Ferrier Industrial, we encourage that dialogue. Bring us your challenges—load movement during transport, stability issues in specific storage environments, custom load geometries that don’t fit standard dunnage placement. We’ll work through options with you. We might suggest material grade changes, placement adjustments, or custom dimensions. Or we might identify that dunnage alone isn’t the answer, and other solutions work better.

Our team brings decades of experience supporting demanding operations. We’ve worked with partners managing coil transport, food logistics, construction materials, agricultural products, and pharmaceutical shipments. Each sector taught us something about how loads behave and what dunnage specifications deliver reliable performance. We bring that collective knowledge to conversations with new teams.

Making the Case for Pallet Dunnage in Your Operation

If you’re evaluating whether pallet dunnage makes sense for your facility, frame it practically. What’s the current cost of load movement—goods arriving damaged, time spent repositioning loads, labour injuries from unstable stacks, or lost efficiency from lower stack heights to manage instability? Compare that cost to the investment in dunnage. In most operations, dunnage pays for itself quickly through reduced damage and improved throughput.

We also recommend thinking about dunnage as part of your load restraint strategy more broadly. Dunnage prevents movement at the pallet-to-pallet interface. Straps and restraint systems provide final control if something does go wrong. Together, they create a complete system where goods stay exactly where they’re positioned.

Our team at Ferrier Industrial is ready to help you evaluate pallet dunnage for your operation. Share details about your current loads, your storage and transport environment, and any stability issues you’re managing. We’ll assess whether dunnage is the right solution and what specifications would work best. We’ll provide samples and placement guidance so you can test the approach before committing fully. And we’ll support your rollout with training, supply relationships, and ongoing partnership.

Get in touch with us at Ferrier Industrial. Tell us about your operation, and we’ll discuss how reliable load stability through effective pallet dunnage can improve your safety, your efficiency, and your bottom line.