Using Vacuum Thermoformed HDPE Dunnage Spacers Inside Returnable Totes for Parts that Might Shift or Scratch

When parts are prone to shifting, scuffing, or surface damage in transit, vacuum thermoformed HDPE spacers provide consistent protection inside returnable totes. These custom-fit inserts stabilize components, separate contact surfaces, and maintain orientation—reducing rework, scrap, and packaging waste. This resource shows how to design and deploy HDPE dunnage spacers to improve protection and throughput while keeping your packaging loop fully reusable.

What you’ll learn in this resource:

• Why vacuum thermoformed HDPE is ideal for reusable dunnage
• Design features that prevent movement, abrasion, and deformation
• How to spec spacers for fit, stacking, and line-side ergonomics
• Implementation steps for returnable tote programs with HDPE inserts

Download the guide now and start preventing part damage while lowering packaging costs and waste.

FAQs

Why choose vacuum thermoformed HDPE for spacers?
HDPE offers excellent impact resistance, chemical resistance, and durability. Vacuum forming delivers precise, repeatable geometry tailored to your part and tote, ensuring snug fit and long service life.

Will spacers slow down packing or line-side handling?
No—properly designed spacers include finger grips, orientation keys, and chamfers to speed loading/unloading and reduce ergonomic strain.