Carton Selection and Void Fill
Selecting the right-size shipping carton and matching dunnage to the product, covering the carton size chart and cube and dimensional weight tradeoffs, void fill and cushioning selection by product characteristic, ergonomic setup of the pack workstation, and safe handling of carton stock and cutting tools.
- Audience
- Packing associates, pack area leads, and packaging engineers
- Review cycle
- semiannual
- Last reviewed
- 2026-08-15
- Revision
- 1
Carton Selection and Void Fill: what is in the procedure
8 sections. Regulatory language is fixed and passes through verbatim. Sections marked customized get rewritten around your facility, your equipment, and your job titles.
- 01
Purpose
FixedThis procedure establishes how a packer chooses a shipping carton and the dunnage that goes in it, and how the workstation is set up so that choice can be made quickly and repeatedly without injury.
- 02
Scope
CustomizedThis procedure applies to the selection of shipping cartons, mailers, and bags and the selection and application of void fill and cushioning at a manual pack station...
- 03
Responsibilities
CustomizedPackers select the smallest carton that protects the contents, match the dunnage to the product, and keep their station set up so materials are within easy reach.
- 04
Procedure: Selecting the Carton
FixedCarton choice is a decision with three constraints, and taking them in order gets it right the first time: it must hold the contents, it must leave room for cushioning, and it must be the smallest size that does both.
- 05
Procedure: Selecting and Applying Void Fill
FixedVoid fill and cushioning are different jobs.
- 06
Procedure: Ergonomic Workstation Setup and Material Handling
CustomizedA pack station is worked thousands of times a shift, so a small reach in the wrong place becomes an injury over a month.
- 07
Exception Handling
CustomizedStop and resolve rather than packing around the problem whenever any of the following occurs: no stocked carton size fits the contents, the correct carton or dunnage type is out of stock at the station...
- 08
References
Fixed29 CFR 1910.176 Handling materials, general.
Regulatory references
Carton Selection and Void Fill: 29 CFR 1910.176(b)
Every SOP generated from this template cites the paragraphs below, with a plain-language summary of what each one requires. Citations are informational and are not legal advice.
Each employer shall be responsible for the safe condition of tools and equipment used by employees, including tools and equipment which may be furnished by employees.
| Standard | Title | What it requires |
|---|---|---|
| 29 CFR 1910.176(b) | Handling materials, general: secure storage | Storage of material must not create a hazard. Bags, containers, bundles, and other material stored in tiers must be stacked, blocked, interlocked, and limited in height so that the storage is stable and secure against sliding or collapse. |
| 29 CFR 1910.242(a) | Hand and portable powered tools: safe condition of tools | The employer is responsible for the safe condition of tools and equipment used by employees, including tools and equipment that may be furnished by the employees themselves. |
| 29 CFR 1910.132(d) | Personal protective equipment: hazard assessment and equipment selection | The employer must assess the workplace to determine whether hazards are present that require personal protective equipment, select and require the use of PPE that protects against the identified hazards, communicate the selection to affected employees, and ensure the equipment fits the employee properly. |
| 29 CFR 1910.22(a) | Walking-working surfaces: general requirements | Walking-working surfaces must be kept in a clean, orderly, and sanitary condition, free of hazards such as sharp or protruding objects, loose boards, spills, and debris that create slip, trip, or fall hazards. |
Compliance checklist
Carton Selection and Void Fill: what an inspector looks for
Carton stock, corrugate bundles, and dunnage cases are stacked square and stable, within the height limit, and never leaned against a wall, rack upright, or workstation
29 CFR 1910.176(b)
Cutters, tape guns, and dispensers are inspected before use and any tool with a failed guard or loose blade is tagged out and removed from service
29 CFR 1910.242(a)
A documented hazard assessment covers the pack station, and the selected personal protective equipment including cut-resistant gloves is provided in a size that fits each packer
29 CFR 1910.132(d)
The station floor and surrounding walkway are kept clear and dry, with corrugate, banding, and loose fill cleared as work proceeds
29 CFR 1910.22(a)
Every carton passes a shake test before sealing and is the smallest stocked size that holds the contents with cushioning clearance on all faces
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This page is informational and is not legal advice. Have a qualified safety professional review any procedure before it goes into service at your facility.