The Global Plastic Dunnage Market was valued at USD 694 Million in 2023 and is projected to reach USD 1,057.38 Million by 2030, growing at a Compound Annual Growth Rate (CAGR) of 6.20% during the forecast period. This growth is being driven by increasing demand across the automotive, aerospace, and electronics sectors, the rapid expansion of e-commerce logistics, and a pronounced industry-wide shift toward reusable and sustainable packaging materials that reduce operational costs and environmental impact.

As global supply chains grow more complex and industries place greater emphasis on damage-free transit, the spotlight is on the key manufacturers who are driving innovation, engineering precision, and greener packaging pathways. In this blog, we profile the Top 10 Companies in the Plastic Dunnage Industry—a mix of global packaging giants, specialty fabricators, and reusable transport pioneers shaping the future of protective packaging worldwide.

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📺 1. Sonoco Products Company

Headquarters: Hartsville, South Carolina, USA
Key Offering: Custom Plastic Dunnage, Thermoformed Trays, Reusable Packaging Solutions

Sonoco is one of the most recognized names in industrial packaging globally. Its plastic dunnage solutions serve high-demand sectors including automotive, electronics, and consumer goods. The company designs precision-fit thermoformed dunnage that protects components throughout complex supply chains, reducing damage rates and improving efficiency.

Sustainability Initiatives:

• Committed to sustainable packaging innovation with recyclable and reusable dunnage options

• Ongoing investment in material science R&D to reduce plastic usage without compromising protection

• Active partnerships with automotive OEMs to standardize returnable packaging programs

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Plastic Dunnage Market – View in Detailed Research Report

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&#9️⃣ 2. ORBIS Corporation

Headquarters: Oconomowoc, Wisconsin, USA
Key Offering: Reusable Plastic Dunnage, Bulk Containers, Totes, and Pallets

ORBIS Corporation is a leading manufacturer of reusable packaging systems, including plastic dunnage inserts and bulk containers. The company primarily serves the automotive, food and beverage, and consumer products industries. Its products are engineered to replace single-use packaging, delivering long-term cost savings and environmental benefits through closed-loop supply chain programs.

Sustainability Initiatives:

• Closed-loop reusable packaging programs that dramatically reduce waste in manufacturing supply chains

• Dunnage systems made from post-consumer recycled content where applicable

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&#8️⃣ 3. UFP Technologies

Headquarters: Newburyport, Massachusetts, USA
Key Offering: Custom Foam & Plastic Dunnage, Thermoformed Packaging, Engineered Components

UFP Technologies specializes in highly customized protective packaging solutions, including foam-based and rigid plastic dunnage for medical devices, aerospace components, and industrial equipment. The company’s engineering-led approach allows it to develop dunnage products tailored to exact dimensional and protective specifications, making it a preferred partner for precision-sensitive industries.

Sustainability Initiatives:

• Development of lightweight plastic dunnage to reduce shipping weight and fuel consumption

• Emphasis on recyclable materials and reduced packaging footprint across product lines

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&#7️⃣ 4. Corplex (formerly Buckhorn)

Headquarters: Milford, Ohio, USA
Key Offering: Reusable Plastic Containers, Dunnage Trays, Automotive Packaging Systems

Corplex, operating under the rebranded identity of the former Buckhorn packaging brand, is a well-established supplier of reusable plastic packaging and dunnage solutions. With deep expertise in automotive supply chain packaging, Corplex delivers dunnage systems specifically designed to protect high-value components such as engine parts, body panels, and electronic assemblies during transit and storage.

Sustainability Initiatives:

• Returnable packaging programs that eliminate single-trip dunnage waste

• Robust lifecycle management services to extend the usable life of dunnage assets

Download FREE Sample Report:
Plastic Dunnage Market – View in Detailed Research Report

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&#6️⃣ 5. NEFAB GROUP

Headquarters: Jönköping, Sweden
Key Offering: Industrial Packaging, Plastic Dunnage Systems, Engineered Crating Solutions

NEFAB GROUP is a global industrial packaging company operating in over 30 countries, with a strong footprint in Europe, Asia-Pacific, and North America. Its plastic dunnage portfolio is designed to meet the rigorous demands of aerospace, automotive, and heavy equipment industries. NEFAB’s engineering teams collaborate directly with clients to design optimized dunnage solutions that minimize product damage and reduce total packaging costs.

Sustainability Initiatives:

• Packaging optimization studies that reduce material usage and lower logistics carbon footprints

• Reusable and returnable packaging frameworks integrated into global supply chain programs

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&#5️⃣ 6. TriEnda Holdings LLC

Headquarters: Portage, Wisconsin, USA
Key Offering: Thermoformed Plastic Dunnage, Pallets, Material Handling Products

TriEnda is a prominent manufacturer of thermoformed plastic products, including dunnage trays, pallets, and custom packaging solutions primarily for the automotive and industrial sectors. The company’s thermoforming expertise allows for the production of large-format, heavy-duty dunnage that holds up under the rigors of multiple production cycles and repeated shipments, making it a cost-effective choice for high-volume manufacturers.

Sustainability Initiatives:

• Products designed for long service life, reducing replacement frequency and overall plastic waste

• Active exploration of recycled resin integration in standard product lines

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&#4️⃣ 7. Reusable Transport Packaging (RTP Company)

Headquarters: Winona, Minnesota, USA
Key Offering: Custom Plastic Dunnage, Reusable Containers, Specialty Packaging

RTP Company is a specialist in custom-engineered reusable transport packaging, including plastic dunnage systems that serve automotive, electronics, and consumer goods supply chains. The company’s strength lies in its material compounding expertise, enabling it to produce dunnage from specialized plastic formulations that offer unique combinations of impact resistance, chemical resistance, and temperature stability.

Sustainability Initiatives:

• Reusable packaging systems that replace expendable dunnage, significantly reducing per-trip packaging costs

• Custom resin formulations that incorporate recycled material content for specific applications

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&#3️⃣ 8. GWP Group

Headquarters: Swindon, United Kingdom
Key Offering: Correx Dunnage Trays, Plastic Fabricated Packaging, Custom Protective Inserts

GWP Group is a UK-based packaging manufacturer known for its expertise in both corrugated and rigid plastic dunnage solutions. The company serves a broad range of industries including automotive, electronics, and pharmaceuticals, providing bespoke dunnage trays and protective inserts that are manufactured to exact client specifications. GWP’s ability to rapidly prototype and produce custom dunnage in low-to-medium volumes makes it an agile partner for manufacturers with complex or changing packaging requirements.

Sustainability Initiatives:

• Focus on Correx® (corrugated polypropylene) dunnage, which is both lightweight and fully recyclable

• Returnable dunnage programs designed to reduce packaging waste across client supply chains

Download FREE Sample Report:
Plastic Dunnage Market – View in Detailed Research Report

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&#2️⃣ 9. Kaysersberg Plastics

Headquarters: Kaysersberg, France
Key Offering: Twin-Wall Plastic Sheets, Custom Dunnage Fabrication, Protective Packaging

Kaysersberg Plastics is a European leader in the manufacture of twin-wall and multi-wall polypropylene sheets, which serve as the foundational material for a wide variety of plastic dunnage applications. The company’s materials are used extensively in automotive, food and beverage, and agricultural packaging. Kaysersberg’s products are recognized for their excellent strength-to-weight ratio, making them a popular choice for dunnage that must be both protective and easy to handle.

Sustainability Initiatives:

• Polypropylene-based dunnage materials that are 100% recyclable at end of life

• Active development of dunnage solutions incorporating post-consumer recycled polypropylene

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&#1️⃣ 10. Amatech Inc.

Headquarters: Louisville, Kentucky, USA
Key Offering: Custom Thermoformed Dunnage, Fabricated Plastic Packaging, Returnable Packaging Systems

Amatech is a specialized manufacturer of custom thermoformed and fabricated plastic dunnage solutions, serving automotive, appliance, and industrial clients across North America. The company is known for its engineering depth and manufacturing flexibility, allowing it to produce dunnage ranging from simple flat trays to complex multi-cavity configurations that hold multiple parts simultaneously. Amatech’s focus on returnable packaging programs has made it a trusted name among manufacturers seeking to reduce both packaging costs and supply chain waste over time.

Sustainability Initiatives:

• Design-for-reuse philosophy embedded in all custom dunnage development programs

• Collaboration with clients to transition from expendable to returnable dunnage systems

Get Full Report Here:
Plastic Dunnage Market – View in Detailed Research Report

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🌎 Outlook: The Future of Plastic Dunnage Is Smarter and More Sustainable

The plastic dunnage market is undergoing a meaningful transformation. While conventional dunnage materials continue to hold a strong presence across manufacturing and logistics operations, the industry is rapidly pivoting toward reusable, recyclable, and custom-engineered solutions that address both cost efficiency and environmental responsibility simultaneously.

📈 Key Trends Shaping the Market:

• Accelerating adoption of returnable dunnage systems across automotive and aerospace supply chains

• Growing integration of 3D printing and advanced thermoforming for rapid, low-cost custom dunnage prototyping

• Regulatory and corporate sustainability mandates pushing manufacturers toward recyclable material choices

• Expansion of plastic dunnage demand in Asia-Pacific, driven by booming automotive and electronics manufacturing

• Increased e-commerce fulfillment activity creating sustained demand for protective packaging inserts and dunnage

Get Full Report Here:
Plastic Dunnage Market – View in Detailed Research Report

The companies profiled above are not only protecting goods in transit—they are actively spearheading the sustainable transformation of industrial packaging, building smarter supply chains one reusable tray at a time.