What is void fill?

Packaging plays a crucial role in the safety and integrity of products during transit. Among the myriad of packaging materials, void fill stands out for its ability to protect and cushion items within a box, ensuring they arrive at their destination in pristine condition. 

Whether you're a small business owner or part of a large corporation, understanding the different types of void fill and their specific benefits can significantly impact your packaging strategy.

Quick links void fill types:

1. Loosefill/Peanuts: Widely recognized as a traditional void fill material, used to fill empty spaces in boxes to prevent item movement.
2. Crumpled Paper: Commonly used as void fill, it provides cushioning and fills up space effectively.
3. Custom Foam Fabrication: While it does fill space and provide protection, it's often custom-designed to fit specific items, making it more of a tailored packaging solution rather than a general void fill.
4. Spray Foam: Similar to custom foam, spray foam expands to fill voids but is applied on-site and molds itself around the item, offering custom protection. It's more of a protective packaging solution with void-filling capabilities.
5. Air Pillows: A popular void fill choice, air pillows are used to fill empty space and provide cushioning with minimal weight addition.
6. Bubble Wrap: Primarily used for wrapping items for protection, but can also be used to fill voids in packages. It's versatile but more commonly associated with wrapping than void filling.
7. Corrugated/Honeycomb: These materials are used both for structural support in packaging and as void fill, offering a dual purpose. They might not be the first choice when one thinks of void fill, but their use for filling space and providing cushioning cannot be discounted.
8. Suspension Packaging: This is a more specialized packaging solution designed to protect and display the item, usually used for high-value or fragile products.

Types of Void Fill

Void fill materials are essential in preventing product movement and damage during shipping. From eco-friendly options to custom solutions, the choice of void fill can significantly influence both the safety of the items and the unboxing experience for the customer. 

Here's a closer look at the most common types of void fill and their specific applications.

1. Loosefill/Peanuts

Loosefill, commonly known as packing peanuts, are a classic void fill solution characterized by their lightweight, S-shaped pieces. They're designed to interlock and fill voids within a package, providing a cushion to protect items during shipping. 

Loosefill is appreciated for its cost-effectiveness and ease of use, making it a go-to choice for many packaging needs.

Advantages:

• Cost-Effectiveness: Loosefill peanuts are among the most affordable void fill options, making them a popular choice for businesses looking to minimize packaging costs.
• Ease of Use: They can be quickly poured into any box, conforming around products to provide cushioning and support.
• Environmental Options: Biodegradable loosefill made from materials like corn starch offers an eco-friendly alternative without sacrificing protection.

Disadvantages:

• Messiness: Their lightweight and free-flowing nature can lead to a messy unboxing experience, potentially deterring customers.
• Product Movement: For high-value or fragile items, peanuts may not offer sufficient stability, leading to potential damage.

2. Crumpled Paper

Crumpled paper void fill is made by compressing and crumpling paper materials to create a dense, protective layer around products. 

This eco-friendly option is favored for its recyclability and the fact that it requires less storage space, being typically stored on rolls that expand when crumpled, providing effective cushioning and stability for a wide range of products.

Advantages:

• Space Efficiency: Stored on rolls, crumpled paper takes up less warehouse space and can be expanded on-demand to fill voids effectively.
• Recyclability: Paper is easily recyclable, appealing to environmentally conscious brands and consumers.
• Stability: Provides a more stable cushioning compared to loosefill, reducing the likelihood of items shifting during transit.

Disadvantages:

• Compression: Once compressed, paper may not rebound, potentially reducing its effectiveness as a cushion over long distances.
• Moisture Sensitivity: Paper loses structural integrity when wet, posing a risk in humid or damp shipping conditions.
• Equipment Requirement: For high-volume operations, a crumpling machine is necessary, representing an additional investment.

3. Custom Foam Fabrication

Custom foam fabrication involves creating precisely cut foam inserts tailored to fit around specific items, offering unparalleled protection. This method is ideal for high-value or fragile products, ensuring they remain immobile and cushioned against shocks and impacts. 

Despite its higher cost, custom foam's precise fit and superior protection make it a preferred choice for many premium packaging applications.

Advantages:

• Superior Protection: Tailored to fit specific products, custom foam offers unmatched protection, particularly for high-value or delicate items.
• Efficiency: Pre-cut shapes and sizes allow for quick and easy packaging, saving time and labor costs.
• Eco-Friendly Options: Innovations in foam technology have introduced recyclable and green alternatives, aligning with sustainability goals.

Disadvantages:

• Higher Costs: Customization and material costs make foam a more expensive option, potentially impacting packaging budgets.
• Storage Requirements: Unlike flat materials, foam requires more space, which could be a constraint in smaller warehouses.

4. Air Pillows

Air pillows are inflatable void fill solutions that provide cushioning and support to packaged items through air-filled pockets. They are known for their efficiency in storage, as they are supplied flat and inflated on-demand, significantly reducing the need for storage space. 

Lightweight and versatile, air pillows are an excellent option for reducing shipping costs while ensuring product safety.

Advantages:

• Compact Storage: Air pillows are stored flat and inflated on-demand, significantly reducing storage needs.
• Lightweight: Adding minimal weight to packages, air pillows can help lower shipping costs, especially for large or lightweight items.
• Biodegradable Options: Some air pillows are made from biodegradable materials, offering an environmentally friendly cushioning solution.

Disadvantages:

• Air Retention: Over time, air pillows may deflate, especially if not properly sealed, reducing their effectiveness as void fill.
• Dependency: If one air pillow fails, it can compromise the integrity of the entire packaging, potentially leading to product damage.

5. Spray Foam

Spray foam is a dynamic void fill solution that molds itself perfectly to the shape of any product, providing custom-fit protection. This on-demand foam is sprayed into the packaging where it expands and hardens, encapsulating the item in a protective barrier. Ideal for items with irregular shapes or sizes, spray foam offers a versatile and secure cushioning method.

However, it is important to consider its higher cost, chemical composition, and potential for expansion-related damage to sensitive items, alongside its less environmentally friendly nature.

Advantages:

• Custom Fit: Spray foam expands to fill the voids, offering a tailored cushion that molds perfectly around any shaped item, ensuring maximum protection.
• Versatility: This method is suitable for a wide range of products, especially those with irregular shapes that are difficult to protect with standard void fill materials.

Disadvantages:

• Cost: Generally more expensive due to the materials and equipment required.
• Chemical Use: Involves chemicals that may not be suitable for all products and can have environmental implications.
• Expansion Risk: The expanding nature of spray foam can potentially damage delicate items if not carefully controlled.

6. Bubble Wrap

Bubble wrap, the quintessential packaging material, is cherished not only for its protective qualities but also for the satisfying pop it offers. Consisting of a pliable plastic sheet adorned with air-filled bubbles, bubble wrap envelops items, providing a cushioned barrier against impacts and vibrations. 

Advantages:

• Cushioning: The air-filled bubbles provide excellent protection against impacts, reducing the risk of damage during transit.
• User Experience: Bubble wrap adds an element of fun and engagement to the unboxing experience, which can be a subtle yet effective marketing tool.

Disadvantages:

• Storage Space: Bulkier than other void fill options, requiring more storage space.
• Durability: Over time, the bubbles can deflate, especially if exposed to heavy pressure, reducing its effectiveness as a protective layer.

7. Corrugated/Honeycomb

Corrugated or honeycomb packaging stands out for its structural strength and eco-friendliness. Crafted from corrugated cardboard or paper materials arranged in a honeycomb pattern, this type of void fill offers exceptional weight-bearing capacity and effective space filling.

Its design provides a unique blend of rigidity and cushioning, making it an excellent choice for heavy or bulky items that require substantial support during transit.

Advantages:

• Strength: Offers high structural strength, capable of supporting heavier items and filling large voids efficiently.
• Eco-Friendly: Made from recyclable materials, providing a sustainable option for environmentally conscious businesses.

Disadvantages:

• Shock Absorption: While strong, it's not the best at absorbing shocks compared to softer materials, which can be a drawback for extremely fragile items.
• Manufacturing Requirements: Requires specific tooling and equipment to produce, which can be an additional cost.

8. Suspension Packaging

Suspension packaging represents the pinnacle of protective elegance, combining superior shock absorption with an impressive presentation. This innovative approach uses a flexible film to suspend the product within a secure frame, minimizing movement and absorbing impacts. 

This type of void fill is good for small electronics and premium items as suspension packaging elevates the unboxing experience, emphasizing the product's value and quality.

Advantages:

• Product Highlighting: Enhances the presentation of the product, making it ideal for high-end items where unboxing is part of the customer experience.
• Protection: Offers a high level of shock absorption, securing the product firmly within the package and minimizing movement.

Disadvantages:

• Compatibility: Not suitable for products with sharp edges or those that can pierce through the suspension film.
• Cost: Generally more expensive due to the specialized materials and design required.

Void Fill Machines for Automating In-House Processees

Efficiency and innovation play critical roles in meeting both the practical and environmental demands of today's businesses. Recognizing this, the packaging industry has seen significant advancements in machinery designed to optimize and automate void fill processes. 

AirWave Mini Inflatable Pillow Systems

The AirWave Mini Inflatable Pillow Systems represent a leap forward in void fill technology, offering a compact, efficient solution for creating air pillows on demand. These systems are designed for ease of use and are ideal for businesses looking for a lightweight, space-saving void fill option.

• Efficiency and Speed: These systems quickly produce air pillows of various sizes, catering to diverse packaging needs and ensuring items are securely cushioned during transit.
• Space-Saving Design: The compact size of the AirWave Mini systems makes them perfect for operations where space is at a premium, without compromising on the output.
• Sustainability: With options for biodegradable and recyclable materials, these systems align with eco-friendly packaging initiatives, reducing the environmental impact.

Paper Void Fill Systems

Paper Void Fill Systems offer an environmentally responsible and versatile solution for filling voids in packaging. These systems crumple paper to create a dense, protective layer around products, ensuring they remain secure and undamaged during shipping.

• Adaptability: Capable of handling a variety of paper types and sizes, these systems provide flexibility in packaging design and protection levels.
• Environmental Benefits: Utilizing recyclable paper as void fill supports sustainability goals by minimizing waste and promoting the use of renewable resources.
• User-Friendly Operation: Designed with simplicity in mind, these systems allow for quick setup and operation, making them accessible to businesses of all sizes.

Both the AirWave Mini Inflatable Pillow Systems and the Paper Void Fill Systems exemplify the packaging industry's commitment to innovation, efficiency, and sustainability. By integrating these systems into their operations, businesses can not only enhance their packaging processes but also contribute to a more sustainable packaging ecosystem.

Final thoughts

Void fill plays an indispensable role in the packaging industry, offering both protection for products during transit and an enhanced unboxing experience for the end consumer. Each type of void fill material and system offers unique advantages, whether it's in terms of cost-effectiveness, protection level, sustainability, or ease of use.

Are you looking to elevate your packaging strategy with custom solutions tailored to your specific needs? Look no further. 

SmartShield Packaging specializes in offering a wide range of void fill materials and systems designed to enhance product safety, minimize environmental impact, and optimize your packaging operations. 

Contact us today to discover how our custom packaging solutions can transform your shipping and handling process, ensuring your products arrive safely and your customers remain delighted with every unboxing experience.