VOID FILL

• The term “Void Fill” refer to any cushioning and padding to create protection to the goods in transit.

• Void Fill is the stuff that fills the void in a package to keep products from rattling around and being damages in
the hustle and bustle of transit. It is type of material you use, whether it ’s air pillows or papers, to fill the box ’s
empty space to provide protection and an attractive unboxing experience.

• Eliminates the voids within the package and prevent the packaged item from moving around and possibly causing
damage.

WHEN DO YOU NEED VOID FILL?

 If your products are fragile.

 If your products are very heavy
 If your products have corners that could be subject to damage (i.e. books and postcards)
 If your package has significant excess space in it that could cause my products to move around and get bent,
damaged or scuffed while package is in transit.

TYPES OF VOID FILL AND CUSHIONING

PAPER

Paper is a void fill and cushioning product that helps you solve multiple issues within your packaging strategy.
Paper is a good void filler that can be crinkled up to eliminate empty space inside the box. You can get creative with paper
void fill by turning it into shreds for a more attractive unboxing experience. There are plenty of paper crumpling machines
that can be installed on your workstations for automation purposes.

Paper also provides good protection for products inside the box, especially when used to wrap individual items.
You can protect delicate objects by wrapping them in paper, and then you can fill any leftover void space with more
crumpled paper. As you can see, paper has a number of applications in void fill and cushioning.

This type of void fill and cushioning is a great option for e-commerce, especially with brands that advertise about
sustainability and recycling. The paper used for packaging is usually 100 percent recyclable and often made with
recovered materials, to begin with. Consumers who are concerned about green packaging will greatly appreciate your use
of paper.
Advantages

 Easy to customize and use for branding purposes.

 Lots of recycled options.

 Doesn’t take too much storage space.

Disadvantages

 A lot of material needed to provide decent protection due to compression.

 Dusty

Machine Model and Specification

 PAPER: 18”-24” Wide: 30lb or 40lb

 Types of Paper: recycled kraft, virgin kraft, bogus and vci

BUBBLE WRAPPING

Bubble wrap is a common void fill and cushioning product that ’s used for multiple applications. This type of void
fill and cushioning material is a wonderful option for fragile items because it has a lot of unique benefits, such as being
moldable and providing a high level of protection. Bubble pouches are also available in multiple sizes to make the
packaging process run even smoother.

While bubble wrap has been popular in the past, it is slowly declining due to one of its greatest flaws:
recyclability. As modern consumers become more aware of their packaging materials and how they affect the
environment, the need for recyclable materials is becoming more inevitable. Bubble wrap is not being manufactured with
a high percentage (or any percentage) of recyclable materials. It ’s also rare that a consumer would know how to recycle
their bubble wrap if they chose to worry about it at all.

Advantages

 Good protection for fragile items.

 Versatile (interleaving, Wrapping and Cushioning)

 Doesn’t add too much bulk.

Disadvantages

 Big rolls take up lot of storage space.

 Hard to recycle (disposal at specific drop off points only)

Machine Model and Specification

Sealed Air Sheeting System Accu-Cut™

Model 480

Maximum Material Width: 50"

Size: 70"W x 54"L x 50"H

Weight: 280 lbs.

Power: 110 VAC, 5 Amp

Maximum Production Rate: 15 sheets/min. (20" length);

20 sheets/min. (10" length)

Model 760

Maximum Material Width: 78"

Size: 102"W x 54"L x 50"H

Weight: 330 lbs.

Power: 110 VAC, 5 Amp

AIR PILLOWS

This void fill and cushioning option is quickly rising to the top of the packaging industry and is being used by
many e-commerce companies. Air pillows are thin sheets of plastic that are pumped with air, sealed by heat, and then used
to pad products within a box. They are frequently stored in compact rolls of plastic sheeting before being inflated by an
automatic machine.

Air pillows provide a high level of protection and they can fill the empty space of a box to help brace products
inside. Air pillow machines are often small in nature and they can be easily integrated into the work station. Many
suppliers and distributors can offer custom perforated rolls at your desired length, so you always get the exact number of
air pillows you need for your specific application.

Advantages

 Lightweight and Reusable.

 Offer basic protection.

Disadvantages

 Needs expensive machinery to inflate

 Not fit for heavy items or anything with sharp edges.
 Takes up of a lot space within the package.
Machine Model and Specification

FOAM

Foam can be used as a void fill material; it’s more often used to provide cushioning for a product. Foam
cushioning comes in many different formats, including pouches, sheets, and more.

Foam sheets can be layered between products that are stacked within a box. One common application of this
method can be seen in the cookware industry where plates and pans are often packaged with foam sheets between each
piece of a set. Foam pouches can be used to fully envelop an item for incredible protection. A foam pouch can be sealed
with tape or by heat.
 Another unique type of foam cushioning is called Instapak. This type of foam expands up to 27 times its size once
activated by hand at room temperature. You can use this to cushion almost any type of product, regardless of size. It
provides durable cushioning and bracing inside the box for heavier items.

PEANUTS

Packing peanuts or packing noodles, are a common loose fill packaging and cushioning material used to prevent
damage to fragile objects during shipping. They are shaped to interlock when compressed and free flow when not
compressed. They are roughly the size and shape of an unshelled peanut and commonly made of expanded
polystyrene foam. 50–75 millimeters (2-3 in) of peanuts are typically used for cushioning and void filling packaging
applications.

Peanuts, like bubble wrap, are one of those void fill options that are declining in popularity. They are difficult to
recycle and are often an annoyance to most consumers because they have a tendency to stick to other surfaces. Peanuts are
made of expanded plastic that’s been created with an injection of air.

Peanuts do provide effective protection, but they also require a lot of warehouse space compared to other
materials like paper or air pillows (before they are filled). Peanuts cannot be kept compact before use, so you ’ll have to
keep a designated amount of space for them.

Peanuts are also quite difficult to recycle. Many consumers are not going to take the extra steps it would require
for them to recycle this void fill material. However, peanuts can be made with recycled materials unlike bubble wrap,
which is not often made with recovered materials. Lush serves as a good example of a company that has transformed
peanuts to be eco-friendlier, but they are one of the only companies that come to mind.

Advantages

 Effective for rapidly filling up spaces.

 Offer basic protection.

 Cheap and Reusable.

Disadvantages

 Not fit to fragile items.

 Costly and unsustainable to ship.
 Foam can be used as a void fill material; it’s more often used to provide cushioning for a product. Foam
cushioning comes in many different formats, including pouches, sheets, and more. Foam is good for products that
can’t be scratched.