Top Mistakes Companies Make When Installing Dunnage Airbags and How to Avoid Them

In the logistics and shipping industry, ensuring that cargo reaches its destination safely is a top priority. One of the most effective tools for securing cargo during transport is the dunnage airbag. These inflatable bags fill voids between cargo, preventing shifting, reducing damage, and keeping shipments stable. However, improper installation can lead to inefficiencies, damage, and increased costs. Here, we explore the most common mistakes companies make when installing dunnage airbags and provide guidance on how to avoid them.

1. Choosing the Wrong Size or Type of Airbag

A common mistake is selecting an airbag that does not match the void space or weight of the cargo. Too small, and it won’t fill the gap; too large, and it may put undue pressure on the cargo or be difficult to install. Additionally, different cargo types require different airbag materials paper, woven polypropylene, or vinyl each with its own strength and flexibility characteristics.

How to Avoid This Mistake:

• Measure void spaces carefully before selecting airbags.
• Match the bag’s size, material, and weight capacity to your cargo and transport method.
• When in doubt, consult the manufacturer or supplier for guidance.

2. Improper Inflation

Even the right airbag can fail if it is overinflated or underinflated. Underinflation allows cargo to shift during transport, while over inflation can cause the bag to burst or exert uneven pressure, potentially damaging the load.

How to Avoid This Mistake:

• Use a pressure gauge to inflate airbags to the recommended level.
• Avoid guessing or “eyeballing” inflation.
• Recheck inflation after placement, as some bags settle slightly after initial inflation.

3. Incorrect Placement

Airbags are only effective when placed correctly. Placing them off-center, against sharp edges, or too close to the walls of a container can compromise their performance. Multiple small airbags placed incorrectly can create uneven pressure, causing cargo to shift unexpectedly.

How to Avoid This Mistake:

• Position airbags centrally between cargo items to ensure even pressure.
• Avoid contact with sharp edges or surfaces that could puncture the bag.
• Use edge protection or padding when necessary.
• Do not overcrowd the space with multiple bags if one properly sized bag is sufficient.

4. Ignoring Environmental Factors

The environment and transport conditions play a significant role in airbag performance. Temperature fluctuations, humidity, and transportation mode (truck, rail, or ship) can affect the bag’s durability and stability. A bag that works well for a short truck trip may fail during a long sea voyage if the environmental conditions are not considered.

How to Avoid This Mistake:

• Select airbags designed to withstand the specific transport environment.
• Consider temperature, humidity, and vibration during transit.
• Inspect and store airbags properly before use to prevent damage.

5. Skipping Training and Standard Procedures

Even with the right equipment, human error can undermine cargo protection. Companies often assume that using airbags is straightforward, leading to inconsistent installation and higher risk of failure.

How to Avoid This Mistake:

• Establish clear Standard Operating Procedures (SOPs) for airbag installation.
• Train all relevant staff on correct sizing, placement, and inflation techniques.
• Conduct regular inspections to ensure compliance with SOPs and correct usage.

Conclusion

Dunnage airbags are an excellent solution for securing cargo, but their effectiveness depends entirely on proper installation. Avoiding mistakes like choosing the wrong size, improper inflation, incorrect placement, ignoring environmental factors, and skipping staff training can dramatically reduce cargo damage and associated costs.

By adopting careful planning, proper procedures, and staff training, companies can maximize the benefits of dunnage airbags, ensuring safer and more efficient transport of goods.