Void Fillers

Paper Void Fill

Paper void fill is versatile and can be crumpled, folded or dispensed into shapes that fill gaps around products.

It is often suitable for eCommerce and general warehouse packing because operators can adjust the quantity for different carton sizes.

Paper cushioning systems can improve consistency at higher-volume stations by supplying material in a controlled format rather than requiring staff to improvise with loose sheets.

Air Pillow Packaging

Air pillows consist largely of air captured inside lightweight film.

Because material is inflated at the packing station, uninflated rolls can occupy substantially less storage space than large volumes of pre-filled cushioning.

Air pillows work especially well for filling larger voids around relatively lightweight products.

They are not automatically appropriate for sharp or extremely heavy items, which may puncture or compress the film.

Air Bubble Cushioning

Inflatable bubble material provides a different structure from simple pillow void fill and can be useful where additional surface cushioning is required.

It may be wrapped around products as well as used to occupy empty space.

For businesses considering inflatable systems, the most useful comparison is not simply the machine price. Consider film consumption, throughput, storage footprint, operator time and suitability for your product range.

Right-Sizing the Carton First

Void fill should not be used to compensate for unnecessarily large boxes.

A smaller carton can reduce filler consumption, parcel volume and the amount of movement that needs controlling.

Before changing void fill, analyse whether the carton range is appropriately sized for the products being shipped.

Packaging optimisation therefore follows a useful order:

• select the smallest practical protective carton;
• position the product;
• identify remaining movement;

add the minimum appropriate blocking, bracing and cushioning.

Avoid Overpacking

More packaging does not always mean better protection.

Overfilling a carton can distort the box, place unnecessary pressure on the product and increase material use.

The best package keeps the product appropriately restrained while maintaining enough cushioning for the expected distribution environment.