Paper void fill is exactly what it sounds like: paper used to fill the empty space inside a box that would otherwise let the product shift and get damaged in transit. It's been used in large fulfilment operations for years, and it's increasingly popular with smaller ecommerce businesses too — mainly because it's faster to use than bubble wrap, takes up less storage space than foam peanuts, and goes straight into the recycling bin.
This guide covers the different types of paper void fill, what each one is good for, and how to decide which works best for your operation.
Why switch from plastic void fill to paper?
The practical case for paper void fill is stronger than most people expect before they try it. The environmental benefits are obvious — paper is recyclable, biodegradable, and doesn't end up in landfill or the ocean the way plastic does. But the operational benefits are just as compelling.
Storage. Bubble wrap comes on large rolls that take up significant warehouse space. Paper void fill — whether loose rolls or dispenser boxes — has a much smaller footprint. You can store more packing capacity in less space.
Speed. Pre-cutting bubble wrap is slow. Scooping foam peanuts is messy. Pulling paper from a dispenser and scrunching it takes two seconds per handful and requires no cutting, measuring, or tools.
Customer perception. Increasingly, customers notice and respond to packaging choices. A box that arrives padded with crumpled paper or kraft tissue feels considered. A bag of polystyrene peanuts feels dated. For brands where the unboxing experience matters, paper sends a better signal.
Disposal. Paper void fill can go straight in the customer's recycling bin. Bubble wrap and foam peanuts can't. This sounds like a small thing but it genuinely affects how customers feel about your packaging.
The different types of paper void fill
Paper void fill isn't a single product — there are several different formats, each suited to slightly different applications.
Crumpled kraft paper (loose or roll)
The most basic form of paper void fill. Sheets or a continuous roll of kraft paper are crumpled loosely by hand and used to fill gaps, wrap products loosely, or layer around fragile items.
This is the least expensive entry point and works well for low-to-medium volumes where speed isn't a critical factor. It requires no equipment, no consumables other than the paper itself, and produces no waste beyond the paper used.
The limitation is consistency — crumpling by hand produces different amounts of cushioning depending on how tightly the paper is scrunched, which can make it harder to standardise packing across a team.
Best for: Low-volume packing, ad-hoc wrapping, operations that want to try paper void fill without any investment.
Centrefeed dispenser rolls
A paper roll housed in a dispenser box — pull from the centre of the roll, tear to length, scrunch, and use. No equipment required beyond the box itself.
This is the format our eComFill™ paper void fill uses, and it strikes a good balance between speed, cost, and simplicity. The 375mm width covers most standard box footprints in one or two pieces, and a 300m roll goes a long way even on a busy packing bench. No machine, no power, no setup.
Best for: Ecommerce operations of most sizes, businesses replacing bubble wrap without wanting to invest in a machine.
→ View eComFill™ centrefeed rolls
Machine-crumpled paper pads
For higher-volume operations, paper void fill machines crumple paper automatically into consistent pads or strips. The machine takes a roll of flat paper and processes it into formed cushioning at speed — much faster than hand-crumpling and more consistent in output.
The trade-off is cost and footprint. A paper void fill machine is a significant investment (typically £500–£3,000+ depending on capability), takes up bench space, and requires a power supply. It also needs regular paper roll changes, which adds a consumable to manage.
For businesses packing hundreds of orders a day where void fill speed is a bottleneck, the investment pays back quickly. For lower volumes, a dispenser roll is a better starting point.
Best for: High-volume fulfilment operations where void fill speed and consistency are critical.
Tissue paper and wrapping paper
Lighter than kraft void fill, tissue paper and wrapping paper are used more for presentation than protection. They wrap products to prevent scuffing, add colour and texture inside the box, and create a more premium unboxing experience.
They're not effective void fill in the structural sense — they don't provide cushioning against impacts — but they work well in combination with a structural void fill material, or for products that don't need cushioning and just need to arrive looking well-presented.
Best for: Premium brands, gift packaging, fashion, beauty — anything where presentation inside the box matters.
→ View wrapping paper and tissue
Corrugated paper rolls
Corrugated paper — a thin layer of fluted paper, usually without a liner — can be cut and wrapped around products to provide lightweight cushioning. It's particularly effective for products with hard edges that might otherwise punch through thinner paper, and for wrapping items that need to be kept separate from each other inside a box.
It's not the fastest void fill format, but it's more robust than flat kraft paper and works well for irregularly shaped products where a consistent pad format doesn't conform easily to the shape.
Best for: Products with edges or irregular shapes, multi-item orders where items need to be separated.
Choosing the right format for your operation
Most operations suit one of two approaches:
Start with a centrefeed dispenser roll if you're currently using bubble wrap or foam peanuts and want to make the switch without any capital outlay. The eComFill™ dispenser format works straight out of the box, costs very little to get started, and handles the majority of ecommerce packing applications well.
Consider a machine if you're packing at high volume and void fill is a measurable bottleneck — the time-and-motion maths usually stack up quickly at 300+ orders per day where void fill is a significant part of each pack.
Add tissue or wrapping paper if you're also thinking about presentation, particularly for gifts, fashion, or subscription boxes.
What paper void fill doesn't replace
It's worth being honest about limitations. Paper void fill is excellent for filling space and providing general cushioning, but for heavily fragile products — glassware, ceramics, precision electronics — it may not be sufficient on its own. For these products, foam inserts or air cushion packaging may provide more reliable and consistent protection.
For most ecommerce applications though — clothing, accessories, homeware, books, gifts, non-fragile consumer goods — paper void fill handles the job well and costs less per order than bubble wrap once you factor in storage, handling, and time.
Want to try it before you commit?
We're happy to send samples so you can test paper void fill on your own packing bench before ordering in quantity. Call us on 02476 611234 or get in touch online — we've been helping businesses improve their protective packaging setups for over 20 years.
Related products: Paper Void Fill | eComFill™ Dispenser Roll | Corrugated Paper | Wrapping Paper | All Void Fill
Paper Void Fill — Types, Uses, and How to Choose the Right One