Void Fill

Void fill refers to materials used to fill empty space inside shipping boxes. Its job is to prevent products from moving around during transit, absorbing shocks and protecting items from the inevitable drops, vibrations, and compression that happen during shipping.

Types of Void Fill

Air Pillows

• Pros: Lightweight, low cost, easy storage
• Cons: Can pop, not recyclable (usually)
• Best for: Light items, filling large voids

Packing Paper (Kraft Paper)

• Pros: Recyclable, versatile, professional look
• Cons: Heavier than air, takes time to crumple
• Best for: Wrapping fragile items, sustainable brands

Bubble Wrap

• Pros: Excellent protection, reusable by customers
• Cons: Not eco-friendly, adds weight
• Best for: Fragile items, individual wrapping

Packing Peanuts

• Pros: Flows around odd shapes
• Cons: Messy, customer complaints, environmental concerns
• Best for: Irregularly shaped items (though falling out of favor)

Foam Inserts

• Pros: Precision fit, maximum protection
• Cons: Expensive, requires custom sizing
• Best for: High-value electronics, precision equipment

Paper Padding/Honeycomb

• Pros: Sustainable, expandable, professional
• Cons: More expensive than basic options
• Best for: Eco-conscious brands, gift items

Choosing the Right Void Fill

Void Fill Best Practices

1. Right-size boxes first - Less void = less fill needed
2. Wrap items individually - Then fill remaining space
3. Items shouldn’t move - Shake test your packed box
4. Don’t over-pack - Too much pressure damages too
5. Consider unboxing - What impression does it create?

Void Fill and Shipping Costs

Void fill affects dimensional weight:

• Larger boxes = higher DIM weight
• More void fill = more weight (slightly)
• Optimal: smallest box that protects adequately

Example savings:

• 18" × 12" × 10" box = DIM 15.5 lbs (UPS)
• 14" × 10" × 8" box = DIM 8.1 lbs (UPS)
• Same product, 50% less shipping cost

Sustainability Considerations

Customer preferences are shifting:

• 60%+ prefer recyclable packaging
• Plastic void fill receives complaints
• Paper-based options growing rapidly

Sustainable alternatives:

• Recycled kraft paper
• Compostable air pillows
• Mushroom-based packaging
• Paper honeycomb systems

Automating Void Fill

High-volume shippers often use:

• Paper cushioning machines (Ranpak, Sealed Air)
• Air pillow makers (Pregis, STOROpack)
• Right-size box machines (Packsize, Sparck)

These systems reduce waste and improve consistency.