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Shipping a product is a test of survival. Your box will get tossed, stacked, and bumped. If there is space inside, your product will slide around. This movement is the number one cause of broken items.
Smart businesses do not leave room for chance. They fill the gaps. From choosing the right custom boxes from a reliable manufacturer, like Silver Edge Packaging, and working with the box design to choosing the right void fill, all matter for product safety.
This blog will explain everything you need to know about void fill packaging. It will help you protect your goods, save money, and make your customers smile.
What Actually Is Void Fill Packaging?
As the name suggests, void fill packaging is the material used to fill the empty space inside your box, mostly a shipping box.
When you choose a box to ship your product, there might be some empty space inside it. Void fill plugs those extra spaces. It acts as a soft cushion that locks your product so it won’t move during transit.
Without it, your item slams into the walls of the box during transit. With it, your item stays safe and snug from your warehouse to the customer’s doorstep.
According to the International Safe Transit Association (ISTA), proper void fill can reduce product damage rates by up to 60%.
Common Types of Void Fill Packaging
Not all fillers are the same. Here are the most common void fill packaging options available today.
Paper-Based Fillers
Made of paper pulp, they are easy to use, easy to store, and highly flexible to customize.
Plus, there are some amazing paper-based filler options you can choose from, including:
- Choose crumpled kraft paper that provides durable cushioning for heavy or fragile items.
- Go with crinkle-cut paper, which is both protective and decorative, to protect premium goods.
- Use silk tissue paper to protect and present luxury products flawlessly.
Paper fillers are recyclable, eco-friendly, and easy to store in rolls or fans. You can simply expand them whenever you need.
Packing Peanuts
Packing peanuts are small, loose pieces of foam that you can pour into a box until it is full. They flow into every single nook and cranny. Although they are small, packing peanuts provide excellent shock absorbers.
What are the types of packing peanuts to choose from?
- Traditional Foam Peanuts: These foam peanuts are lightweight, shock-absorbing, but they are made of plastic.
- Starch-Based Peanuts: They dissolve in water, are highly biodegradable, and will not harm the environment.
Bubble Wrap
You must have seen those plastic sheets filled with small air bubbles, right? That’s bubble wrap. It is famous for its popping sound and great protection. You can wrap this void filler directly around your product. It provides a thick shield that prevents scratches and dents on delicate products’ surfaces.
But did you know that bubble wrap was actually invented in 1957 as wallpaper? Yes, it was before it ended up being repurposed for void fill packaging.
Air Pillows
Air pillows are small, clear plastic bags filled with air. They arrive at your warehouse as flat, empty film. A small machine pumps them full of air right before you use them. The best part? Because air pillows are, of course, mostly air, they weigh almost nothing, keeping your shipping costs low.
Air pillows were mentioned to save up to 90% storage space, making them a preferred choice for many businesses as a warehouse favorite.
| Void Fill Packaging | Appearance | Feature |
| Paper-Based Fillers | Rough for crumpled kraft, silk for soft tissue paper | Easy to use, easy to store, recyclable, and highly flexible |
| Packing Peanuts | Small, loose pieces of foam. | Excellent shock absorber |
| Bubble Wrap | Plastic sheets filled with small air bubbles | Provides a thick shield that prevents scratches and dents |
| Air Pillows | Small, clear plastic bags filled with air | Space-saving, weighing almost nothing, and keeping shipping costs low |
Why Void Fill Packaging Matters?
If you try to skip void fill to save a few pennies, it will be a costly mistake. Void fill packaging is a must-have tool for any modern supply chain. Shipping is brutal on packages. A typical box drops multiple times on its journey. It rides on bumpy conveyor belts. It slides around the back of delivery trucks. If a box has space, the sides can easily crush under the weight. When a box collapses, the product inside takes the hit.
Here are the valid reasons why void fill packaging is essential for businesses today.
It Prevents Product Shifting
Items that move are items that break. If you ship a heavy glass bottle in an empty box, it will slide. It will strike the cardboard walls with great force. Movement equals breakage. Heavy items sliding inside a box strike with force. Void fill packaging acts as a brake, holding products firmly in the center of the box.
It Minimizes Damage
Accidents happen. Drivers drop boxes, and stacks fall over. Void fill packaging acts like a pillow during a crash. It absorbs the kinetic energy from a drop. This means that the filler takes the shock, so your product does not have to.
It Enhances Your Product’s Perceived Value
Imagine a customer opens your box. They see a neatly wrapped item nestled in clean, beautiful paper. This, for sure, makes them feel like opening a high-end gift. Properly packing your product tells customers that your product is exclusive and valuable. Most importantly, this type of unboxing shows that you care about quality.
It Elevates Your Brand’s Image
Your shipping box is a handshake with your customer. Using cheap, messy, or excessive plastic can hurt your reputation. Using neat, eco-friendly paper or clean air pillows elevates your brand. It shows you are professional and modern. And we know that customers appreciate thoughtful packaging.
It Is Cost-Saving
Broken products ruin your profits. Just think about it. You have to pay for a return shipment. You have to send a replacement item for free. You also risk losing that customer forever.
Investing a few cents in void fill packaging saves you hundreds of dollars in damage claims. Yes, it protects your bottom line.
Risks of Skipping Void Fill
So, what do you think will happen if you skip void fill packaging?
Things that your business would surely not want, such as:
- Higher damage rates (up to 11% of shipping spend lost)
- Negative reviews and customer dissatisfaction
- Increased carbon footprint from reshipping replacements
- Long-term brand reputation damage
How to Choose the Right Void Fill Packaging?
Alright, now that you know what void fill packaging is and why it matters, how to choose the right one? Every product has unique needs. You must match your filler to the specific item you need to ship.
Heavy or Sturdy Goods
Heavy items need strong support. Light plastics will pop or flatten under heavy weights.
Best Choice: Crumpled Kraft paper.
Why: Thick paper compresses into a dense, tough cushion. It blocks heavy items from moving. It holds its shape even under high pressure.
Lightweight or Non-Fragile Items
If your product is already tough and light, you just need to fill the empty space quickly.
Best Choice: Air pillows.
Why: They fill massive gaps instantly. Plus, they add zero weight to your box, keeping your dimensional weight fees as low as possible.
Uniquely Shaped or Multi-Part Products
Some boxes hold items with strange angles, like a toolset or a collection of small bottles.
Best Choice: Packing peanuts.
Why: Loose peanuts flow like liquids. They fill irregular gaps that sheets of paper or bubbles cannot reach, ensuring total coverage.
Luxury & Fragile Goods
Fragile goods like electronics, glassware, or high-end cosmetics need the utmost protection along with beautiful presentation.
Best Choice: Bubble wrap or custom foam.
Why: These fillers wrap tightly around your product and ensure it won’t move. They also provide a strong barrier protection against scratches and shocks. Your product will look neat and professional at the same time.
| Product Type | Best Void Fill | Why |
| Heavy or Sturdy Goods | Crumpled kraft paper |
|
| Lightweight or Non-Fragile Items | Air pillows |
|
| Uniquely Shaped or Multi-Part Products | Packing peanuts |
|
| Luxury and Fragile Goods | Bubble wrap or custom foam | Provide a strong barrier protection against scratches and shocks |
The Takeaway
Void fill packaging is not something that fills a box. It helps keep your products safe, helps you make profits, and helps your company look good. Void fill packaging may not be something that people notice. Yet, it makes a big difference. It is the difference between something breaking and a customer being happy.
Whether you use paper, biodegradable peanuts, bubble wrap, or air pillows, the important thing is to choose carefully according to your product’s needs. And at Silver Edge Packaging, we help you choose the right void fill packaging for your product.
Remember, your packaging is like a handshake with customers. Make it strong, professional, and good, for the earth. Nevertheless, void fill packaging keeps your products safe, makes your company look better, and helps you ship with confidence.
