Void fill compared - which material protects best?

What job does void fill do in the box?

Void fill has two jobs: it holds the goods in the centre of the box and it dampens the shocks that hit the parcel during transit. As a rule of thumb, allow 3 to 5 cm of cushioning between the goods and the box wall on every side.

There is a difference between void fill, which simply fills empty space, and true cushioning, which absorbs energy. Heavy or fragile goods need real cushioning, while light items are often fine with pure void fill.

Paper, chips, air pillows or corrugated?

The four common materials differ clearly in fill performance, weight and cushioning. Paper cushioning and corrugated fill are heavier but dimensionally stable, while air pillows and chips are extremely light and fill large volumes cheaply.

• Paper cushioning: crumpled kraft paper, easy to handle, high tear strength, recyclable with waste paper.
• Loose fill chips: bulk fill made from starch (biodegradable) or recycled foam.
• Air pillows: on-demand inflated film cushions, minimal storage as a flat roll.
• Corrugated void fill: inserts, grids and edge protectors made from the same fibre as the box.

What about sustainability and handling?

Paper and corrugated board go straight into the waste paper stream and are easiest for customers to dispose of. Starch chips are compostable, and air pillows made of recyclable film save weight and postage but must be collected separately.

Handling comes down to throughput: paper and air-pillow systems dispense material at the touch of a button at the packing bench, while loose chips need a hopper with an outlet. If you ship in volume, a fixed dispenser saves noticeable time.

Frequently asked questions