Everything You Need to Know about Dunnage Bags (from one of the world’s leading manufacturer)
Dunnage bags, sometimes known as airbags, are essential tools in the world of logistics and shipping. They play a crucial part in securing goods and cargo during transit, preventing damage, and ensuring that products reach their destination in perfect condition.
But have you ever wondered how dunnage bags are made, what they’re made from, and what makes them so useful in the world of shipping? Well you’re in the right place! In this article, we will take a closer look at the manufacturing process of dunnage bags and explore the fascinating world of rubber engineering.
What is a dunnage bag?
Dunnage bags are inflatable bags designed to fill the voids or empty spaces in shipping containers, trucks, or railcars. They are typically used to prevent the shifting or movement of cargo during transportation. Dunnage bags are placed between cargo items and inflated once in position to provide stability and support, effectively immobilising the products and reducing the risk of damage during transit. They are available in various sizes and configurations to suit the diverse needs of various clients.
If you can imagine the small inflatable plastic bags you get in a parcel when you order something online to stop your order getting broken in the box, dunnage bags are like this on a larger scale!
What are dunnage bags made from?
The Checkmate Heavy Weight Dunnage Bags are constructed from a combination of materials, but reinforced rubber plays a key role in their composition!
The outermost layer of a dunnage bag is typically made of high-strength, tear-resistant materials. While rubber is the primary material, it is reinforced with nylon or polyester to enhance durability. This outer layer acts as a protective shield against external elements and potential damage and is designed to be airtight, weatherproof and resistant to tears and breaks. It is also capable of being repaired if it becomes damaged in use.
Checkmate Lighter Weight Dunnage Bags have a woven plastic outer and an inner layer, often referred to as the bladder, which is made from an impermeable material. This layer is designed to be airtight, ensuring that the bag can be inflated and maintain its pressure. It also serves as the primary component responsible for distributing air evenly within the bag to provide support and stability.
Specialised hot bonding, welding and adhesives are then used to join the various parts together securely. These are selected to create a strong and reliable bond between the materials. Dunnage bags are also equipped with inflation and deflation valves, to ensure airtight sealing. They are crucial for the easy and efficient inflation of the bag when it’s placed in a shipping container or vehicle.
Incorporating these materials and components allows dunnage bags to fulfil their role in cargo security and protection during the transit of goods. The combination of high-strength materials, and detailed construction, ensures that these inflatable bags can withstand transportation while maintaining their integrity.
Why are dunnage bags made from rubber?
The choice of rubber as the primary material for dunnage bags is due to its unique combination of elasticity, strength, durability, airtight properties, resistance to environmental factors, and cost-effectiveness. These characteristics make rubber an ideal material for ensuring the safe and secure transportation of goods in the modern logistics industry.
Dunnage bags are primarily made from rubber due to several key reasons:
Elasticity and flexibility
Rubber is known for its excellent elasticity, which allows dunnage bags to expand and contract during inflation. This also means that the bags can conform to the shape of the cargo and provide a snug fit, reducing the risk of cargo movement!
Strength and durability
Rubber is a strong and durable material, making it capable of withstanding the stresses and pressures that may occur during shipping. It can resist tearing, punctures, and abrasion, ensuring the bags’ longevity and reliability.
Airtight
Rubber is naturally airtight, which is essential for maintaining the pressure within the dunnage bag. An airtight seal is crucial to prevent air leakage and maintain the bag’s inflation for the duration of the shipment.
Weather resistant
Rubber is resistant to a wide range of environmental factors, including moisture, temperature fluctuations, and exposure to chemicals. This makes dunnage bags suitable for a variety of shipping conditions and ensures they perform consistently.
How are dunnage bags made?
The journey of a dunnage bag begins with the selection of the rubber material. Natural rubber, synthetic rubber, or a combination of both can be used. The choice depends on the bag’s intended use and the specific properties required, such as elasticity, tear resistance, and environmental considerations!
Once the rubber material is selected, it is cut into specific shapes. These shapes will form the various components of the dunnage bag, including the outer layers and inner chambers. Precision cutting is crucial to ensure a proper fit and the desired performance characteristics.
Dunnage bags are constructed with multiple layers of rubber, and each layer has a distinct purpose. The innermost layer, often called the bladder, is responsible for holding and distributing air. It needs to be airtight and strong enough to withstand pressure. The middle layer provides additional strength and stability, while the outer layer is designed to be durable, tear-resistant, and protect against external elements.
Rubber engineers use specialised adhesives to bond these layers together. These adhesives are chosen to ensure that the layers stay securely attached, creating a strong and reliable product. Precise adhesive application is crucial, as any imperfections could compromise the bag’s performance.
Dunnage bags need a valve system to inflate and deflate them easily. Rubber engineers install high-quality valves, which are generally made of plastic or metal, at a designated location on the bag. The valve must be airtight and user-friendly, allowing for quick and efficient inflation.
Before dunnage bags are ready for market use, they undergo rigorous quality control measures. These include pressure tests, visual inspections, and leak detection to ensure that the bags are free from defects and ready to perform flawlessly in real-world conditions.
Every Checkmate dunnage bag is stress-tested to the highest degree, with 10% of each batch receiving an additional high pressure proof test. Checkmate Flexible Engineering has set the standard for air loss with ABS certified and witnessed tests. The company’s BS EN 9001 2015 quality assurance system is registered with SGS, a UKAS approved company.
Depending on customer requirements, dunnage bags can then be customised with features such as printed branding, special shapes, or added reinforcements. Our rubber engineers work closely with our clients to develop dunnage bags that meet their specific needs.
Checkmate Flexible Engineering is committed to delivering high-quality dunnage bags that meet the demanding standards of the logistics and shipping industry. With our expertise in rubber engineering and a dedication to innovation, Checkmate Flexible Engineering continues to provide innovative solutions that protect cargo, reduce costs, and streamline logistics operations.
If you’re in search of reliable dunnage bags for your cargo protection needs, look no further than Checkmate Flexible Engineering. With a wealth of expertise in rubber engineering and a commitment to quality, our dunnage bags are engineered to safeguard your valuable cargo during transit. Contact us today to explore our range of customisable dunnage bags and discover how we can provide tailored solutions to meet your specific shipping requirements.