Void Fill Packaging: Air Pillows vs Paper Void Fill – Which Is Best for Your Business?
Void Fill Packaging: Air Pillows vs Paper Void Fill – Which Is Best for Your Business?
When products are packed into a shipping box, there is often a gap between the product and the inside of the carton. Left unfilled, this space allows the product to move around during handling and transportation, increasing the risk of damage.
This is where void fill packaging comes in.
Void fill is used to occupy empty space inside a carton, helping to prevent products from moving while also providing additional cushioning during transport. For ecommerce businesses, fulfilment operations, manufacturers and distributors, choosing the right void fill can make a significant difference to product protection, packing speed, storage space, material consumption and overall packaging cost.
There is no single void fill solution that is ideal for every application. Two of the most popular options today are inflatable air packaging and paper void fill, with each offering distinct advantages.
At Maxpack, a range of void fill materials and machines is available, including air pillow systems, paper void fill systems and manual dispensing solutions.
View the full range of void fill packaging and machines at Maxpack.ie
What is void fill packaging?
Void fill is packaging material used to fill the empty space inside a box or carton.
Its primary purpose is to stop products moving around inside the outer carton. During transportation, parcels can be subjected to vibration, drops, impacts, compression and sudden changes in direction. If the product has room to move inside the box, these forces can be transferred directly to the product.
A well-designed void fill system keeps the product appropriately positioned within the carton and can provide a degree of cushioning between the product and the carton walls.
Common void fill materials include:
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Air pillows
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Air cushions
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Inflatable air bags
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Paper void fill
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Crumpled paper
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Bubble material
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Loose-fill packaging
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Foam products
For modern packing operations, however, paper and inflatable air systems have become particularly attractive alternatives to traditional loose-fill materials.
Air Pillows and Air Cushions
Air pillows are manufactured from thin plastic film which is inflated with air at the packing station.
Instead of storing large volumes of finished packaging material, the film is supplied on compact rolls and converted into air-filled pillows or cushions when required.
This is one of the major advantages of air-based void fill.
For example, Maxpack supplies AirPac Pillow film in a range of formats, including 200mm x 100mm, 200mm x 150mm, 200mm x 200mm and larger formats. The company also offers Fill-Air and Sealed Air New Air systems.
See AirPac air pillow packaging at Maxpack.ie
Why use air pillows?
1. Very low storage requirement
One of the biggest advantages of inflatable packaging is that the material is stored as film rather than as finished cushions.
A roll of film occupies relatively little warehouse space compared with the volume of finished void fill it can produce.
This can be particularly valuable for ecommerce and fulfilment companies where warehouse space is expensive.
2. Extremely lightweight
Air pillows consist predominantly of air, with only a relatively small quantity of film.
This means they add very little weight to the finished parcel.
For businesses shipping large numbers of parcels, reducing packaging weight can contribute to lower overall shipping costs, particularly where carrier pricing is affected by parcel weight.
3. Very fast packing
An air pillow machine can produce void fill on demand at the packing station.
The operator can produce exactly the quantity required rather than having to retrieve pre-made packaging from a storage area.
This can improve packing-line efficiency, particularly in high-volume ecommerce environments.
4. Excellent for filling large voids
Air pillows are particularly effective when a relatively large amount of empty space has to be filled.
They can be placed around the product, above it or between multiple products to prevent movement.
5. Clean and convenient
Unlike loose-fill chips or some traditional void fill materials, air pillows are clean, lightweight and easy for the packer to handle.
They can also be easily removed by the customer when opening the package.
When should you use air pillows?
Air pillows are particularly suitable for:
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Ecommerce fulfilment
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Clothing and fashion products
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Consumer electronics
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Household products
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Cosmetics
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Books and media
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Small and medium-sized retail products
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Multi-product orders
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Lightweight products
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Operations packing hundreds or thousands of parcels per day
They are especially attractive where large quantities of void fill are required but warehouse space is limited.
For a business shipping 500 parcels per day, for example, storing hundreds of boxes of pre-made void fill can quickly become inconvenient. An on-demand air system allows the material to be produced as it is required.
Air Pillows vs Air Cushion/Bubble Material
It is important to distinguish between simple air pillows and larger air cushions or bubble-style air packaging.
Air pillows are primarily designed to fill voids and prevent product movement.
Air bubble or cushion material can provide a higher degree of surface protection and can be used for wrapping, interleaving or cushioning individual products.
Maxpack offers the Sealed Air New Air IB Nano system, which produces air-filled packaging material, as well as other inflatable film options.
View the Sealed Air New Air IB Nano system on Maxpack.ie
This type of system can be particularly useful where a company needs both void fill and cushioning protection.
For example, a fragile glass item may need more than simply stopping it from moving inside the box. It may also require a protective layer between the product and the carton.
Paper Void Fill
Paper void fill is the other major option for modern packing operations.
Paper systems convert paper from a compact roll or fan-folded format into a larger, crumpled or formed structure which can be placed around products.
Maxpack offers paper void fill materials including 50gsm and 70gsm fan-folded paper, as well as paper dispensing and converting systems.
See paper void fill systems at Maxpack.ie
Why choose paper void fill?
1. Paper-based packaging
For companies looking to reduce their dependence on plastic packaging, paper can be an attractive option.
Paper void fill can also be easier for the end customer to understand and dispose of as a paper-based packaging material, subject to the specific material, coatings, contamination and local recycling arrangements.
2. Excellent product presentation
Paper can provide a more traditional and premium packaging appearance.
For brands selling products where the unboxing experience is important, paper void fill can look considerably more substantial than lightweight plastic air pillows.
3. Excellent for heavier products
Paper generally has more inherent mass and structure than inflatable air pillows.
This makes it particularly useful for products that are heavier or have sharp edges that could potentially puncture or displace lighter inflatable packaging.
4. Good for products with irregular shapes
Crumpled paper can conform around products of different shapes and can be used to create a relatively tight pack.
This makes it particularly useful for products that don't fit neatly into the carton.
5. Versatile packing technique
Paper can be used as:
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Top-fill
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Bottom-fill
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Side-fill
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Interleaving
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Wrapping
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Blocking and bracing
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General void filling
Paper Void Fill Machines
For low-volume packing operations, a simple manual paper dispenser can be sufficient.
Maxpack offers a Manual Void Fill Paper Dispenser, providing an economical way of dispensing paper at the packing station.
For businesses with higher packing volumes, powered paper converting machines can significantly improve productivity.
Maxpack currently lists systems including:
PAPER PAC ECO
The PAPER PAC ECO is designed as an entry-level paper void fill system and is suited to businesses looking to move towards an on-demand paper packaging solution.
PAPER PAC PRO
The PAPER PAC PRO provides a higher-capacity paper converting solution for businesses with greater packaging requirements.
FasFil® EZ™
Maxpack also lists the FasFil® EZ™ Void Fill System, providing an automated method of converting paper into protective void fill.
The important point is that a paper system doesn't simply replace a box of loose paper. The machine converts the supplied paper into a controlled void fill material at the packing station, helping to make the packing process more consistent.
Air or Paper – Which Is Better?
The answer depends on the product and packing operation.
There is a tendency to ask:
"Is paper better than plastic?"
From a packaging engineering perspective, that is not necessarily the right question.
The better question is:
"Which material provides the required product protection with the lowest overall packaging, storage, labour and transport impact?"
A packaging material that uses considerably more material, takes up substantially more warehouse space or adds unnecessary weight may not necessarily be the most efficient solution.
The correct choice should consider the entire packaging process.
Air Pillows vs Paper Void Fill – Comparison
| Feature | Air Pillows | Paper Void Fill |
|---|---|---|
| Material | Plastic film | Paper |
| Storage requirement | Very low | Low |
| Weight | Extremely low | Higher |
| Large voids | Excellent | Excellent |
| Heavy products | Moderate | Very good |
| Irregular products | Good | Excellent |
| Fragile products | Good | Good to very good |
| Packing speed | Very high | High |
| Clean handling | Excellent | Very good |
| Customer perception | Lightweight/modern | Traditional/premium |
| Plastic reduction | Not suitable where eliminating plastic is the priority | Excellent option |
| Machine footprint | Generally small | Small to medium |
| Best application | High-volume ecommerce | Ecommerce, retail and industrial |
| Shipping weight impact | Minimal | Higher |
| Storage efficiency | Excellent | Very good |
What About Bubble Wrap?
Bubble wrap remains an excellent protective packaging material, but it should not necessarily be regarded as a direct replacement for void fill.
Bubble wrap is primarily a cushioning and wrapping material.
Air pillows are primarily a void filling material.
For example, if you are shipping a ceramic vase inside a large carton, simply filling the empty space with air pillows may not be enough.
A better packaging design could involve:
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Wrapping the vase in bubble material or another cushioning material.
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Placing the wrapped product inside an appropriately sized carton.
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Using air pillows or paper to prevent movement inside the carton.
This is an example of why good packaging design often involves more than one packaging material.
The Importance of Using the Right Size Carton
One of the most overlooked aspects of void fill is the carton itself.
If a business consistently uses boxes that are substantially larger than the products being shipped, no void fill system will completely solve the underlying problem.
The first objective should always be to select an appropriately sized carton.
Void fill should then be used to deal with the remaining unavoidable void space.
This approach can reduce:
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Packaging material consumption
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Void fill consumption
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Carton costs
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Warehouse space requirements
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Shipping volume
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Packing time
For high-volume ecommerce operations, carton right-sizing can therefore be just as important as choosing the correct void fill material.
How Much Void Fill Should You Use?
The objective isn't to completely fill the box with packaging material.
The objective is to prevent excessive product movement while providing appropriate protection.
Too little void fill can allow the product to move and become damaged.
Too much can waste material, increase packing time and potentially increase packaging costs.
The correct quantity depends on:
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Product weight
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Product fragility
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Product shape
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Carton dimensions
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Number of products per carton
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Transport conditions
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Required level of cushioning
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How much movement can be tolerated
A packaging trial is often the best way to establish the optimum quantity.
Choosing the Right Void Fill Machine
The machine should be selected according to the packing operation rather than simply based on the machine price.
Important considerations include:
Number of parcels packed per day
A business packing 50 parcels per day has very different requirements from a fulfilment operation packing 2,000.
Number of packing stations
If several operators are packing simultaneously, decentralised tabletop machines can be particularly effective.
Product mix
A company packing predominantly small, lightweight products may favour air pillows.
A company shipping heavy, irregularly shaped products may prefer paper.
Available storage space
Where warehouse space is limited, inflatable systems have a significant advantage because the film is stored compactly before inflation.
Desired packing speed
For high-throughput operations, on-demand automated or semi-automated systems can dramatically improve the availability of void fill at the packing station.
Maxpack Void Fill Solutions
Maxpack offers a range of void fill solutions suitable for different packing environments.
The current range includes:
AirPac Eco – an entry-level protective air filling machine suitable for businesses looking for an economical on-demand air packaging system.
AirPac Pro – a higher-capacity air filling machine for more demanding packing applications.
Fill-Air Cyclone® – an on-demand air bag void fill system designed to produce air bags at the packing station. Maxpack describes it as suitable for replacing loose fill and other bulky void fill options.
Sealed Air New Air IB Nano – an air packaging system capable of producing air-filled protective material.
PAPER PAC ECO – an entry-level paper void fill system.
PAPER PAC PRO – a higher-capacity paper void fill solution.
FasFil® EZ™ – an on-demand paper void fill system.
Manual Void Fill Paper Dispenser – a simple solution for lower-volume packing applications.
Maxpack also supplies the associated consumables, including AirPac pillow film, Fill-Air film and fan-folded paper.
View Maxpack's void fill machines and packaging systems
Which Void Fill Solution Is Right for Your Business?
As a general guide:
Choose air pillows if:
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You pack a high number of parcels.
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Your products are relatively lightweight.
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You have limited warehouse space.
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You need to fill relatively large voids.
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Packing speed is important.
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You want a lightweight packaging solution.
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You want to produce void fill on demand.
Choose paper void fill if:
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You want a paper-based packaging solution.
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Product presentation is important.
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You are packing heavier or irregular products.
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You need a material which can provide blocking and bracing.
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You want to reduce your reliance on plastic void fill.
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Your customers value paper-based packaging.
Consider air bubble/cushion material if:
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Products are fragile.
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Surface protection is important.
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You need to wrap products as well as fill voids.
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You need cushioning against impact rather than simply preventing movement.
Consider a combination of materials if:
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Products are particularly fragile.
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You have a wide variety of products.
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Some products require wrapping while others only require void fill.
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You need maximum flexibility across several packing stations.
The Best Void Fill Is the One That Fits the Packaging Process
There is no universal "best" void fill material.
The right solution is the one that provides the required level of protection while minimising material consumption, labour, storage requirements and shipping impact.
For many ecommerce operations, air pillows offer an extremely efficient way of filling large volumes of void space while keeping material weight and storage requirements low.
For companies looking for a paper-based solution, on-demand paper void fill provides excellent flexibility and can be particularly effective for heavier or irregular products.
For fragile products, air cushioning, bubble material and paper can all play a role, depending on the level and type of protection required.
The most effective packaging operations therefore don't simply ask which material is cheapest. They consider the total cost of packaging – material, labour, storage, machinery, shipping weight, product damage and customer experience.
Need Help Choosing a Void Fill System?
Choosing the correct void fill system can be difficult without looking at the products being packed and the way they are currently being packed.
At Maxpack, we can help businesses assess their existing packing operation and identify whether air pillows, air cushioning, paper void fill or a combination of solutions would be most appropriate.
From a simple manual paper dispenser through to on-demand air and automated paper void fill systems, there are solutions available for everything from small ecommerce businesses to high-volume fulfilment operations.
Explore Void Fill Packaging & Cushioning at Maxpack.ie
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