Dunnage Bags in the Life Sciences Industry

The life sciences sector operates within a complex and highly regulated supply chain where the safe and timely transportation of temperature-sensitive, fragile, or high-value products is essential.

Biopharmaceuticals, clinical trial materials, vaccines, and diagnostic devices are frequently exposed to extended transit durations, varied climatic conditions, and multi-modal transport networks.

Transportation Challenges in the Life Sciences Sector

The life science sector faces persistent challenges, including exposure to temperature fluctuations, physical shocks, and vibrations during transit. Many life sciences products are vulnerable to even minor deviations, making protection during transportation a key component of risk management.

The products often require stable environments, precise handling, and uninterrupted cold chain management across complex global supply routes. As a result, packaging and logistical systems must be engineered to mitigate the risks inherent to high-value, high-sensitivity cargo.

Role of protective packaging

Protective packaging solutions serve as a defense against these logistical challenges. Beyond thermal control, packaging stabilises cargo, prevents movement, and absorbs impact forces during loading, transport, and unloading.

Dunnage bags, for instance, secure palletised shipments within containers and trailers, reducing the likelihood of product displacement or damage caused by shifting loads. This stability reduces the risk of product displacement, mechanical stress, or breakage during handling, transit, or customs inspections.

Understanding Dunnage Bags

Dunnage bags are inflatable devices used to fill void spaces between cargo in shipping containers, trucks, or railcars. Their primary purpose is stabilising loads by preventing sliding, tipping, or shifting during transport.

These bags are lightweight yet durable and made from kraft paper, polyethylene, or woven polypropylene. They are available in various sizes and strengths to accommodate cargo types and transportation modes.

Key features of dunnage bags include:

• High Load-Bearing Capacity: Designed to withstand significant pressure without bursting.
• Customisable Sizes: Adaptable to various cargo dimensions and container gaps.
• Ease of Use: Quick inflation and deflation processes simplify their application.
• Reusability: Many dunnage bags are reusable, aligning with sustainability goals.

Advantages of Using Dunnage Bags

Within the life sciences industry, the protection of goods during transport is directly linked to product viability and regulatory compliance. Dunnage bags offer several benefits that make them particularly suited:

Applications in the Life Sciences Industry

The life sciences sector deals with often fragile, temperature-sensitive, or chemically reactive products. Dunnage bags provide a reliable solution for securing such cargo during transit. Below are some specific applications:

Transportation of Pharmaceuticals: Products, including tablets, capsules, vaccines, and biologics, require careful handling to prevent physical damage or exposure to adverse conditions.

• Stabilise pallets of pharmaceutical goods within containers.
• Prevent tipping or crushing of packages during transport.
• Ensured compliance with Good Distribution Practices (GDP) by maintaining product integrity.

Shipping Medical Devices: Medical devices such as diagnostic equipment or surgical instruments are often bulky and delicate.

• Protect devices from impact damage caused by shifting loads.
• Secure irregularly shaped items within shipping containers.
• Minimise vibrations that could affect device calibration.

Biotechnological Products: Products like cell cultures or enzymes are susceptible to environmental changes and physical disturbances.

• Maintain stability during long-distance transport.
• Reduce risks associated with sudden movements or shocks.
• Safeguard high-value shipments from damage.

Considerations When Choosing Dunnage Bags

Selecting the appropriate strength level and dimensions ensures effective load stabilisation. Dunnage bags are classified by levels indicating maximum pressure capacity and load-bearing ability.

Choosing the right size depends on the gap between cargo units and container dimensions to maximise surface contact and performance. The effectiveness of dunnage bags depends on several technical factors:

Load-Bearing Capacity: The load-bearing capacity of a dunnage bag is determined by its material strength and inflation pressure. For instance:

• Level 1 dunnage bags can handle lighter loads (up to 0.55 bar).
• Level 5 dunnage bags are designed for heavy-duty applications (up to 1.5 bar).

Environmental Conditions: Transit routes may expose cargo to varying ecological conditions. Dunnage bags must be capable of maintaining structural integrity under fluctuating temperatures and humidity levels. Material selection should account for potential expansion, contraction, or degradation due to thermal shifts or moisture exposure.

Regulatory Considerations: The use of dunnage bags in the life sciences industry must comply with international regulations governing cargo safety and product integrity:

• Good Distribution Practices (GDP): This ensures that pharmaceutical products remain safe and effective during transportation.
• ISO Standards: Provide guidelines for packaging materials used in securing cargo.
• Association of American Railroads (AAR): Certifies dunnage bags based on their load-bearing capacity and performance under stress tests.

Compliance with these standards ensures product safety and facilitates smooth cross-border transportation.

Best Practices for Implementation

Dunnage bags should be positioned between stable, flat surfaces to ensure even pressure distribution. They must fill the entire void without overextending into open space.

Inflation should follow manufacturer guidelines based on bag size, pressure rating, and cargo weight. Over-inflation increases the risk of bursting, while under-inflation reduces stabilisation effectiveness.

Palletising and Container Loading: Avoid uneven surfaces, overhanging loads, or irregular shapes that compromise contact with the bag. During container loading, gaps between pallets or cargo and container walls should be minimised for optimal dunnage bag placement. Use corner boards or edge protectors if necessary to prevent punctures.

Training Warehouse Staff: Operational staff must be trained in proper dunnage bag selection, inflation techniques, and placement procedures. Training should also cover safety precautions, such as avoiding inflation near sharp edges and checking pressure levels with calibrated equipment.

Proper Inflation: Over-inflation can cause bursting, while under-inflation may result in insufficient load stabilisation. Follow the manufacturer’s guidelines on optimal inflation pressures based on bag size and cargo weight. Use recommended inflation tools to ensure consistent and accurate pressure levels during deployment.