X-Pak Global

Protecting Darrell Lea’s Exported Food Products

Darrell Lea use X-Pak Dunnage Bags with a Portable Inflator


The X-Pak Dunnage Bags & Inflation Unit Solution was introduced to Darrell Lea to help solve a persistent problem the company was facing. Darrell Lea was experiencing significant product damage and flow-on costs due to voids within their export containers. In response, X-Pak provided a solution that would result in increased safety within the warehouse, increased time efficiency, and no product damage in transit.


Prior to implementing the X-Pak solution, Darrell Lea was not using any form of load restraint in their containers. They also had gaps both between their pallets and the last row and container doors. As a result, multiple shipments were arriving at various destinations globally with product damage, leading to significant costs for the company. The damaged products would need to be re-packed at the clients warehouse or reimbursements were given, meaning additional costs overall in the supply chain.

The problem

After conducting a thorough analysis of Darrell Lea’s operations through multiple site visits, it was determined that improvements were necessary in their container packing processes and the implementation of a load securing system. This was essential in ensuring that their products arrived at their destinations damage free

The  Solutions

The solution to Darrell Lea’s problem was the introduction of 120 x 210cm dunnage bags and Portable Inflation Unit (PAM unit). 

The dunnage bags were used to fill voids within the container and reduce product movement, which resulted in preventing product damage.

The average gross weight of the products being secured was approximately 500kg per pallet.

Dunnage Bags

The process

Step 1

After placing goods inside the container, the first step is to place 1 bag between the 2 pallets, ensuring a maximum amount of surface area of the dunnage bags and the pallet is touching. For double height pallets, we suggested a 120cm x 210cm woven dunnage bag. Any voids between 50mm and 400mm can be effectively filled using these bags to prevent load shift and product movement.

Step 2

Using the portable inflation unit, attach the valve of the bag to the nozzle and inflate the bag until the bag is firm and the product is pushed to the side of the container walls or you hear the inflation unit change tone. The portable inflator is geared to correctly inflate a Level 1 dunnage bag to the ideal working pressure for load stability.


Time and Manpower Used Consumables Used

- 1 worker

- No prep time required

- Total Time spent: Approx. 2 minutes

- 2 to 3 120x210cm dunnage bags per container
Dunnage For Shipping Containers
Dunnage For Shipping Containers

Are you looking to prevent damage to your products in a container or reefer?

Don’t risk the safety of your customers or the damage to your valuable cargo. Order your Dunnage Bags today and enjoy peace of mind knowing your goods will be protected during transportation.

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