In ecommerce, logistical, and global supply chain environments, the way a product is packaged is just as important as the product itself. Proper packaging protects goods, improves customer experience, and prevents costly returns. One essential but often underestimated component of secure packaging is void filler packaging.

Whether you’re sending electronics, clothing, cosmetics, or industrial components, filler packaging plays a key role in keeping items stable and safe when being transported. In this blog, we cover everything you need to know, including what it is, when to use it, the different types available, and how to choose the right option for your packaging needs.

What is void filler packaging?

Void filler packaging is the materials used inside a parcel to fill empty space between the product and the outer package. The main aim of it is to secure the item, reduce the chance of damage from impact, and create a more structured package.

When a box is too big for its contents, items are more likely to move around during handling and transit. Void filler solves this by stabilising the product inside and absorbing shock or vibration. Depending on the type of product you’re shipping, you might need a certain type of void filler to cushion, hold, or simply fill space.

Void filler also improves the customers’ experience of unboxing their package, especially for ecommerce and retail businesses. A neatly packed item surrounded by clean, protective fill shows that your brand cares, you’re professional, and you prioritise attention to detail.

When should filler packaging be used?

Filler packaging should be used whenever there’s too much space within your packaging and it could result in your products moving, breaking, or becoming scuffed. This is particularly important if:

• Your product is fragile or has delicate components

• Your items come in different shapes and sizes

• You’re using stock boxes that might not perfectly fit every product

• The contents of your parcel are valuable or time-sensitive

• Your item is part of a set or bundle and separation during transit could cause confusion or damage

Filler packaging isn’t just about protection, it’s about consistency, customer satisfaction, and cost reduction. Damaged products can lead to returns, complaints, and even negative reviews, which are bad for business. Using void filler can help avoid these issues.

What are the different types of void filler packaging?

There are several types of void filler packaging on the market, each with their own set of benefits. The best choice for your business will depend on what you’re packing, how it’s shipped, your sustainability goals, and how much you’re sending daily. Here are some of the most common options available.

Paper filler packaging

Paper void fill is one of the most popular and eco-friendly options. It’s usually made from recycled or recyclable kraft paper, and is a great choice for businesses looking to reduce plastic use. It’s ideal for ecommerce and retail businesses, or if you're sending light to medium-weight parcels. This is because the paper can be crumpled, folded, or layered to fill empty space and cushion products.

Key benefits:

• 100% recyclable and biodegradable

• Lightweight and cost-effective

• Suitable for a wide range of items

• Works well with automated dispensers

Air bag filler packaging

Air pillows or air bag fillers are made from lightweight plastic film. They can be inflated when needed by using a small machine. They create a cushion of air that absorbs shock and fills voids with minimal material use. If you're sending electrical products, boxed products, or bulk items, they're a great option.

Key benefits:

• Very lightweight and help to keep shipping costs low

• Space-saving, as they can be inflated when needed

• Clean and professional appearance

Foam filler packaging

Foam void fillers usually come in foam rolls, sheets, or expanding foam. They're known for conforming to product shapes. This offers excellent protection for delicate or high-value products in particular. They’re ideal if you’re shipping glassware, electronics, medical devices, or fragile components.

Key benefits:

• Offer superior cushioning and shock absorption

• Suitable for sensitive or precision items

• Available in sheets, wraps, or sprays

Loosefill packaging

Also known as “packing peanuts”, loosefill is a filler that is made from polystyrene or other biodegradable materials. It pours into voids easily and can completely surround items. If you ship irregular shaped or multiple small items in one box, this is a great option.

Key benefits:

• Fast and easy to use

• Biodegradable options available

• Reuseable in many cases

Tips for choosing the right void filler packaging

Choosing the right void filler depends on what you’re packing and how you’re packing it. Here are some of our top tips to help you make a decision:

• Product type and fragility - if you’re shipping fragile items, consider foam or dense paper for better cushioning. Sturdier products might only need basic void fillers with lighter material like air pillows or loosefill.

• Customer expectations - if you’re shipping directly to customers, aim to choose clean, minimal-looking fillers like kraft paper or recyclable air pillows. This will create a better brand impression.

• Volume and speed - automated paper or air systems are ideal if you have a high packing volume. Manual fillers work well for lower-volume businesses.

• Storage space - consider how much space your filler will take up in your warehouse. If you only have a small space or a mobile packing station, air pillows and compact paper rolls are ideal.

• Environmental goals - if sustainability is a priority, opt for recyclable, biodegradable, or paper-based void fillers. These not only help the environment but appeal to eco-conscious customers.

Speak to us about your void filler packaging

At Plus Packaging, we supply a wide range of void filler packaging solutions to suit every type of business and product - from recyclable paper and biodegradable loosefill, to high-performance bubble and dunnage bags.

Whether you’re looking to reduce product damage or switch to a more eco-friendly filler packaging solution, our specialist team can advise you on the best option for your business needs. Get in touch with us today to speak with one of our packaging experts and explore our full range of filler packaging products.

Void filler packaging FAQs

What’s the difference between void fill and protective packaging?

Void filler packaging is designed to fill empty space and prevent movement. Protective packaging (like bubble wrap or edge protectors) is used to wrap or shield the product directly. Both can be used together for maximum protection during shipping.

Which void filler is more cost-effective?

Paper filler and loosefill are the most cost-effective for general void fill. For high-volume operations, air pillows can be very economical due to their low weight and space-saving format, particularly when used with on-demand inflating machines.

Can I automate void filler application?

Yes, many paper and air pillow fillers are available with dispensers or machines that automate filler production and application. This is especially useful in high-volume packing operations, helping speed up the process and improve consistency.