Warehouse & Inventory · SOP

Order Packing Dunnage & Void Fill Quality Standard

This procedure defines the six critical checkpoints for selecting carton stock, isolating fragile surfaces, placing dunnage layers, filling lateral voids, sealing with H-tape pattern, and completing a final QC shake test. Every outbound parcel must pass these criteria before label application.

Estimated Time

4 min / parcel

Difficulty

Intermediate

Regulation

ISTA 3A / FedEx TPC

Version

1.0

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Purpose

To standardise the selection, placement, and visual inspection of dunnage and void fill materials for every outbound parcel at the packing station. Consistent application prevents in-transit damage, avoids penalty charges from carrier weight discrepancies, and reduces consumable waste by eliminating over-packing. Compliance with ISTA 3A drop test thresholds requires that internal void fill density prevents product displacement greater than 10 mm under moderate agitation.

Scope

Applies to all packing stations on Shift A and Shift B in the West Fulfillment Building (Pack Zones 1–6). Covers corrugated cartons (ECT-32 minimum), kraft crinkle fill (virgin fibre), 3/16-inch bubble wrap, and 75 mm clear acrylic packing tape. Excludes polybags, rigid mailers, and any automated void-fill machine that has not been calibrated within the preceding 30 calendar days. This standard does not substitute for carrier-specific dangerous goods packaging.

Safety Precautions

CUTBox cutters and tape dispensers must be used with a retractable blade (OLFA SK-10 or equivalent). Never leave blades extended when setting the knife down. All blade changes must be logged on the Pack Zone safety clipboard.
ERGBulk dunnage rolls and bubble wrap reels exceed 25 kg. Use a two-person lift or the RollMule dolly for any reel change. Never lift rolls alone — back injury reports in Pack Zone 3 increased 140% in Q2 last year when single-person lifts were performed.
PPTPacking tape residue and kraft paper dust accumulate on floors. Sweep each workstation at every shift change. Slip hazard Z216.5.1 requires immediate remediation — any spill of water or lubricant must be addressed within 5 minutes.

Required Tools & Materials

Corrugated carton (ECT-32 min, any RSC) — inspected per Step 1 criteria
Kraft crinkle fill (virgin fibre, 500 g/m³ density) — or recycled honeycomb kraft as alternative
3/16-inch bubble wrap — for fragile surface isolation (glass, electronics, polished metal)
75 mm clear acrylic packing tape — for H-tape seal pattern
Digital parcel scale (certified, max 35 kg, resolution 0.01 kg)
Pack station QC checklist (printed, double-sided, waterproof stock)
Retractable box cutter (OLFA SK-10 or approved equivalent)

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Procedure: Step-by-Step

1 Inspect empty carton condition. Select a carton with no more than 2 staple closures, no corner crush exceeding 15 mm, and no visible moisture stains. Discard any carton with crushed corners >15 mm or water damage. Visual reference: hand template — if the crush is larger than a loonie, reject.

2 Load bottom dunnage layer. Place a 75 mm minimum layer of kraft crinkle fill (or honeycomb kraft) on the bottom of the carton. Ensure coverage extends into all four corners with a 50 mm vertical up-turn on each sidewall. Compress test: after placement, press with palm — should not bottom out on carton floor.

3 Center product and isolate fragile surfaces. Position the primary product in the carton centre. Wrap individually each glass, polished, or electronic item with 2 full wraps of 3/16-inch bubble wrap, securing ends with 50 mm clear packing tape. Bubble wrap must extend at least 25 mm beyond the top and bottom of the item.

4 Fill lateral voids and top cushion. Fill all lateral voids between product and carton wall with dunnage to a density where the product cannot shift more than 10 mm when the carton is agitated 10 times by hand. Insert a final top layer of dunnage compressed to minimum 60 mm thickness after lid closure. Use a 2-finger gap test: if you can slide two fingers between product and wall, add more fill.

5 Seal and verify weight compliance. Seal the carton using an H-tape pattern: two strips crossing the centre seam (each strip 75 mm wide, centred), plus four corner locks (50 mm strips at 45° on each bottom corner). Minimum tape overhang beyond each edge: 75 mm. Weigh the sealed carton. If weight exceeds carrier dimension-based threshold (e.g., 22.5 kg for standard parcel), remove excess void fill and re-weigh.

6 Apply shipping label and final QC inspection. Apply the shipping label to the top face, 8 mm from edges, ensuring no bubble pockets under the label. Perform final QC shake test: 10-second moderate agitation — no audible internal movement >10 mm. Stamp or mark 'PASS / DUNNAGE QC' on the side panel with the packer ID. Any failed shake test must be re-opened and re-packed from Step 2.

Order Packing Dunnage & Void Fill Quality Standard

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