The Comprehensive Guide to Void Fill

Enhancing Packaging and Shipping Efficiency
20 July 2023 by
The Comprehensive Guide to Void Fill
Glenn Izard

When it comes to packaging and shipping products, ensuring their safe transit is of paramount importance. Void fill materials play a crucial role in protecting items during shipping and reducing the risk of damage caused by shifting or impacts in transit. In this comprehensive guide, we will explore the significance of void fill, its various types, application methods, and tips to choose the right void fill solution for your specific packaging needs.

Understanding Void Fill and Its Importance

a. What is Void Fill? Void fill, also known as packing material or cushioning, refers to the material placed inside packages to fill empty spaces or voids around products. These voids often occur when the product's size doesn't perfectly match the dimensions of the shipping box. Void fill materials serve two primary purposes:

  1. Protection: Void fill materials cushion the products, preventing them from shifting or colliding during shipping. They absorb shock and impacts, reducing the risk of damage and ensuring that the items arrive at their destination in perfect condition.

  2. Cost-Effectiveness: In addition to protecting products, void fill materials also help businesses save money on shipping costs. Properly filled packages reduce the risk of dimensional weight charges, where carriers charge based on package size rather than weight.

b. Importance of Void Fill: Void fill plays a vital role in customer satisfaction and brand reputation. When customers receive products that are intact and undamaged, they are more likely to trust the brand and make repeat purchases. Additionally, a positive unboxing experience, facilitated by effective void fill, can lead to positive reviews, word-of-mouth recommendations, and increased customer loyalty.

Types of Void Fill Materials

Various void fill materials are available, each with its unique characteristics and applications. Choosing the right type of void fill depends on the product's fragility, weight, and the packaging method. Here are some common types of void fill materials:

a. Bubble Wrap: Perhaps the most widely recognized void fill material, bubble wrap consists of plastic sheets with air-filled bubbles. It provides excellent cushioning and protection against impacts. Bubble wrap is available in various sizes and can be easily cut and customized to fit products of different shapes.

b. Packing Peanuts: Also known as foam peanuts or styrofoam peanuts, packing peanuts are lightweight and resistant to moisture. They fill voids effectively and provide cushioning for delicate items. However, they can be messy and may not be the best choice for environmentally conscious businesses, as they are not easily recyclable.

c. Air Pillows: Air pillows are inflatable plastic pouches that can be quickly filled with air using special machines. They are lightweight, cost-effective, and provide reliable cushioning for various products. Air pillows are space-efficient as they can be filled on-demand, reducing storage space requirements.

d. Kraft Paper: Kraft paper is an eco-friendly void fill material made from recycled paper. It is often used in crumpled form to provide cushioning and fill voids around products. Kraft paper is biodegradable and can be recycled, making it an excellent option for businesses with sustainability goals.

e. Foam Inserts: Foam inserts are custom-molded pieces of foam designed to fit specific products perfectly. They offer superior protection for delicate and high-value items. Foam inserts can be relatively expensive, but they are highly effective for products that require maximum protection during transit.

Application Methods for Void Fill

The choice of void fill material is crucial, but so is the way it is applied within the packaging. The goal is to create a secure and stable environment for the products, minimizing movement during shipping. Here are some common application methods:

a. Surrounding Method: This method involves placing the product in the center of the box and surrounding it with the void fill material. The packing material should be packed tightly to provide maximum protection.

b. Top and Bottom Method: In this method, void fill is placed at the top and bottom of the box, leaving the product suspended in the center. This technique is suitable for lightweight products and can provide effective protection.

c. Complete Encapsulation: For fragile and valuable items, complete encapsulation with void fill material ensures that the product is entirely protected from all sides. Foam inserts are often used for this method.

d. Combination Method: Depending on the product's fragility and weight, a combination of different void fill materials and application methods can be used to optimize protection and cost-effectiveness.

Tips for Choosing the Right Void Fill Solution

Selecting the most appropriate void fill solution for your business involves considering several factors. Here are some tips to help you make the right choice:

a. Product Characteristics: Evaluate the fragility, weight, and dimensions of your products. Fragile items may require more robust and impact-resistant void fill materials, while lightweight items may benefit from cost-effective options.

b. Shipping Distance and Transit Conditions: Consider the shipping distance and the conditions the packages are likely to endure during transit. Longer journeys or rough handling may require more resilient void fill materials.

c. Eco-Friendly Considerations: If environmental sustainability is a priority for your business, opt for void fill materials that are recyclable, biodegradable, or made from recycled materials.

d. Cost-Effectiveness: Analyze your shipping volume and budget to determine the most cost-effective void fill solution. While some materials may be more expensive upfront, they may save you money in the long run by reducing product damage and shipping costs.

e. Branding Opportunities: Some void fill materials, like custom-printed tissue paper or branded packing peanuts, offer opportunities to reinforce your brand identity and create a memorable unboxing experience for customers.

Implementing an Effective Void Fill Strategy

An effective void fill strategy is essential for maximizing protection and minimizing shipping costs. Here are some steps to implement an efficient void fill process:

a. Staff Training: Train your packaging team on the proper application methods for different void fill materials. Ensuring that void fill is used correctly will optimize protection and minimize material waste.

b. Quality Control: Implement regular quality checks to ensure that all packages are appropriately filled with void material. Consistency in the packaging process is essential for maintaining customer satisfaction.

c. Monitor Customer Feedback: Pay attention to customer feedback and reviews related to packaging and shipping. Address any issues promptly and make improvements to enhance the customer experience.

d. Continuously Optimize: Regularly review your void fill strategy and make adjustments as needed. As your business grows and evolves, your packaging needs may change, so be flexible in adapting your void fill approach accordingly.


Void fill is a critical aspect of the packaging and shipping process for businesses of all sizes. The right void fill materials and application methods protect products from damage, reduce shipping costs, and enhance the customer experience. By understanding the various types of void fill materials available, considering product characteristics, and implementing an effective void fill strategy, businesses can ensure that their products arrive safely at their destination, fostering customer satisfaction and brand loyalty. Remember to continuously monitor and optimize your void fill process to stay ahead in the competitive world of e-commerce and shipping.

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