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Introduction
When companies first start shipping products, they usually focus on the basics like boxes, tape, and labels. However, they eventually realize that the box isn't enough and that void fill is easily one of the most overlooked parts of packaging. The empty space inside a container allows products to shift, collide, and even arrive damaged. That’s where packaging filler comes in. Void fill stabilizes and protects the product during shipment, while also creating a memorable unboxing experience.
It’s a misnomer that void fill is optional and only required for fragile items. Whether you’re shipping candles, cups, clothing, or electronics, the presence of void fill determines whether the product arrives intact or flawed.
What is void fill?
In simple terms, void fill packaging is the material used to fill the empty space inside a shipping box. When you open a package and find crumpled paper, air pillows, or crinkle paper, you’ve already encountered void fill doing its job. This fill material helps prevent products from shifting or getting damaged during transit. Packages are often dropped and tossed around. Void fill absorbs the shock the product would otherwise experience if it were empty.
It is easy to confuse void fill with protective packaging, but they serve very different purposes. While protective packaging is wrapped directly around a product to absorb impact, void fill is used to fill the empty space around an item and immobilize it. Many products come wrapped in bubble wrap or paper, but may still slide around in the box.
“What is fill material?” The answer is simple. It is any packaging material used to fill empty space, improve product stability, and prevent shipping damage.
Do you need void fill?
You might be wondering whether or not your products need to be packaged with void fill. This can easily be tested by performing a shake-and-flip test. Place your product in an empty box, seal the package, gently shake it, and listen for any rattling or sliding of the products inside. Repeat these four steps, but instead of shaking it, flip it upside down. If you can feel or hear the items shifting in the package during these two tests, they are likely to collide during transit, and you need fill material to secure the products in place. The goal is to have zero movement, and the void fill’s purpose is just that.
The cost of not using void fill is higher than you might think. Skipping void-fill packaging can lead to higher return rates, replacement costs, and negative reviews from customers who have poor unboxing experiences. Even just a little material goes a long way in preventing damage and keeping your customers’ experiences consistent.
Types of void fill packaging materials:
There are several common types of void-fill materials, and the choice depends on the product being packaged, its fragility, and aesthetic requirements. Below is a breakdown of the six most commonly used packaging materials by type, function, and cost. If you are currently looking for void fill and want to evaluate the best material for your products, read the section below to help you make the best decision.
Paper fill/kraft paper
Kraft paper fill is one of the most commonly used packaging materials because it is simple, versatile, and affordable. It is typically crumpled or rolled up to fill the space around a product.
Best for:
- Moderate protection
- Odd-shaped items
- Everyday shipping needs
Eco/cost:
Kraft paper is typically recyclable and naturally decomposes in the environment without leaving residues behind. You can crumple it by hand or with a crumpling dispenser.
Crinkle cut paper shred
Crinkle-cut paper shred is a decorative filler material used in gift boxes and retail packaging. Its voluminous cushioning provides a unique unboxing experience and enhances product presentation.
Best for:
- Gift packaging
- Luxury products
- Lightweight items
Eco/cost:
Crinkle paper made from paper is usually recyclable; you'll want to check on metallic or plastic shred. However, it can be more expensive than basic void-fill options due to its design, elegant appearance, and weight.
Air pillows
Air pillows are lightweight, inflatable plastic cushions that maximize space and provide protection.
Best for:
- Pre-packaged items
- Clothing
- Electronics in retail packaging
Eco/cost:
Air adds essentially zero weight to a package, thereby reducing fuel consumption. It also takes much less physical material because it primarily requires air. Requires an inexpensive air pillow inflating machine, but uses far less warehouse space due to the compact nature of the uninflated rolls.
Bubble quilt
A bubble quilt is one of the most recognized forms of void fill. It consists of small air-filled bubbles trapped between two layers of plastic film that absorb shock and protect products. The bubble quilt is made of a stiff plastic that is typically rolled around a delicate item.
Best for:
- Fragile/delicate items
- Electronics
- Items prone to damage
Eco/cost:
A bubble quilt is generally recyclable where plastic film is recycled and can help reduce shipping costs because it’s extremely lightweight while still providing excellent protection.
Honeycomb paper
Honeycomb paper is scored and folded into a hexagonal lattice that provides padding and protection for sensitive items. Honeycomb paper protects products by creating a moldable protective element - ideal for highly fragile items.
Best for:
- High protection
- Large or heavy items
- Fragile items
Eco/cost:
Honeycomb paper is 100% recyclable in kraft. The moldable aspects of the fill offer excellent protection for fragile items and may help reduce overall box dimensions, thereby reducing dim weight calculations.
Loose fill/packing peanuts
Packing peanuts are loose, lightweight pieces used to surround products and absorb the movement inside a shipping container.
Best for:
- Irregularly shaped products
- Fragile items
- Filling awkward empty space
Eco/cost:
While most packing peanuts are made from Styrofoam and are non-biodegradable, there are some sustainable alternatives made from starch or recycled materials. Typically, the cost of eco-friendly packing peanuts is higher than that of Styrofoam.
How much void fill should you use?
It can be difficult to know how much void fill to use in a specific box. The key is to fill the box until items don’t rattle and the box can close flat without bowing.
Some of the most common packaging mistakes made are underfilling and overfilling. When boxes are underfilled, empty space remains inside, allowing products to move around during transit. Even a slight amount of movement can lead to damage and ultimately defeat the purpose of the void fill.
Overfilling can cause problems, too. When boxes are overfilled with too much material, the seams of packages become strained and more difficult to properly seal. The packages are also at risk of being opened during transit, which can damage the products or cause them to be lost altogether.
The best way to package an item with void fill is to use just enough material to keep everything secure without putting the box under pressure. As mentioned before, perform a quick shake-and-flip test to check whether you have used the right amount of void fill in your package!
Beyond protection: void fill as a brand experience
Void fill has always served one simple purpose: to keep products protected during transit. Loose paper, peanuts, and bubble wrap prevent damage and ensure orders arrive intact.
But in today’s ecommerce landscape, package filler does more than protect the items in a box. It creates brand perception and tells a story.
The second a customer opens a box, before they even touch the product itself, they experience the packaging's textures, colors, and presentation. Void fill is not just a shipping necessity, but a part of the customer experience with your brand.
Most brands consider fill material to be generic, functional, and forgettable. It is often an afterthought, even though it takes up most of the space inside a box.
Custom void fill can turn simple packaging into a significant part of the brand story. Package fillers like colored crinkle paper and branded air pillows create a unified presentation that elevates the product inside. Branded void fill is more likely to be saved and reused by customers as well.
Research conducted by the National Library of Medicine found that perceptions of simplicity and craftsmanship significantly influence perceptions of usefulness, ease of use, enjoyment and trust (Denison-Day). Likewise, custom branded void fill can contribute to an overall positive unboxing experience for customers.
The visual presentation of packaging matters. Balanced arrangements and color choices make unboxing experiences more appealing and memorable by eliciting positive emotions. According to researcher Benedicte Grinde, color has the ability to enhance visual comfort and people find value in objects that display symmetry and balance. Custom void fill allows businesses to create a cohesive product presentation that reinforces brand loyalty through attention to detail.
Instead of treating package filler like an add-on, DECOfill creates void fill that is essential to product safety while also providing an opportunity to promote your brand identity. Our protective and beautiful fill material helps brands create unboxing experiences that feel intentional, personal, and memorable.
From branded and protective fill to elevated presentation, DECOfill offers a range of packaging fillers designed to enhance your product and maintain your brand image.
Don’t choose. Void fill that protects AND creates an elegant unboxing experience.
Choosing the right void-fill material depends on the product being shipped, your packaging budget, environmental goals, and the brand experience you want to create. For certain items, lightweight air cushions might be ideal for cost and protection, while honeycomb paper may be needed for premium protection and aesthetics. It is also important to consider the environmental effects of various void fills. Most paper packaging materials are compostable and recyclable, aligning with the growing demand for sustainable packaging, while others reduce overall weight, lowering transportation emissions and shipping costs.
Brands focused on customer experience might consider going beyond just product protection. Customizing void fill not only protects products but also reinforces a cohesive brand identity and reliability. When void fill is unique to a brand, customers experience a memorable unboxing amid the multitude of packages they open day-to-day.
Whether a product is an electronic that needs strong protection, a handmade gift that deserves a decorative presentation, or an everyday product in need of sustainable packaging, DECOfill offers customizable solutions designed to protect products and reinforce brand attributes at every point in the customer experience. Explore DECOfill’s branded void fill products and discover options that enhance brand image at no additional cost.
Sources:
Denison-Day, J. L., Muir, S., Newell, C., & Appleton, K. M. (2023, June 22). The role of aesthetics in intentions to use digital health interventions. PLOS digital health. https://pmc.ncbi.nlm.nih.gov/articles/PMC10286978/
Grinde, B., & Husselman, T.-A. (2023, September). An attempt to explain visual aesthetic appreciation. Integrative psychological & behavioral science. https://pmc.ncbi.nlm.nih.gov/articles/PMC10350433/
