Protective Cushioning Compared - Which One Fits?
Air cushions, foam, paper cushioning and moulded inserts protect sensitive goods in very different ways. This guide compares the four cushioning materials by shock absorption, volume and cost, and shows when each option makes sense.
View cushioning materialsWhich cushioning materials are available?
Four material groups have become standard for shipping protection: air cushions (air pillows and film), foam (PE and PU foam), paper cushioning (crumpled and honeycomb paper) and custom moulded inserts. Each group has its own profile of cushioning, volume and price.
Air cushions rely on trapped air and are extremely light. Foam absorbs even repeated impacts thanks to its cell structure. Paper cushioning is recyclable and fills voids cost-effectively. Moulded inserts made of foamed or cut material hold the product in a precise fit.
- Air cushions: very light, large fill volume per cubic metre of storage.
- Foam: high resilience, cushions multiple impacts.
- Paper cushioning: recyclable, ideal for void fill and blocking.
- Moulded inserts: precise fit for sensitive or high-value goods.
How does shock absorption differ?
Protection depends on how the material absorbs the drop energy. Key factors are the resilience after impact and the behaviour under several impacts in a row, which is normal in parcel shipping.
How do volume and cost relate?
Material cost is only part of the equation. Storage volume, packing time and shipping weight often drive the total cost per shipment more than the purchase price alone.
Air cushion systems save storage space because the pillows are filled only at packing. Moulded inserts pay off mainly at high volumes, since tooling or cutting costs are then spread out. Paper cushioning is the all-rounder with a good environmental balance.
- Factor in the shipping weight - paper is heavier than air.
- Account for the packing time per shipment.
- Check recyclability and what customers expect from the packaging.
Frequently asked questions
Which cushioning material absorbs shocks best?
Foam and precise moulded inserts offer the best shock absorption, even under repeated impacts. Air cushions suit lighter goods.
Which material is the cheapest?
Air cushions produced on site and paper cushioning are cheapest to buy and store. Moulded inserts only pay off at high volumes.
How much cushioning do I need per shipment?
As a guideline, keep at least 3 to 6 cm of cushioning between product and box wall so the drop energy is safely dissipated.
Which material is most eco-friendly?
Paper cushioning is recyclable and usually made from recycled paper. PE foam and air cushions can also be recycled when sorted by type.
Looking for the right cushioning?
We supply air cushions, foam, paper cushioning and custom moulded inserts - matched to your product, volume and budget.
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Materials for safe drop and transit protection.
Cost in view
Advice based on volume, weight and quantity.
Wide range
Four material groups for every use case.
Expert advice
Packaging specialists help you choose.