When it comes to packaging, most people think of the outer box. But logistics professionals and packaging experts know that real protection starts from the inside. That’s where void fill materials come in—often underestimated, yet crucial for ensuring safe and damage-free deliveries.

In this article, we’ll explore:

  • Why internal void fill is essential
  • The main types of protective fillers and their advantages
  • How to choose the right solution for your business
 

Why Use Void Fill in Packaging?

A product that’s not securely fixed inside its box is at a much higher risk of damage during shipping or storage. Even the strongest outer packaging can't compensate for a lack of internal protection. Void fill materials serve several key purposes:

  • Absorb shocks and vibrations
  • Stabilize the product inside the box
  • Reduce movement and prevent scratches
  • Improve the unboxing experience
 

Common Types of Void Fill Materials

1. Paper Void Fill

A sustainable and efficient solution made from recycled paper. It can be shaped manually or dispensed through automated machines.

Applications:

  • Electronics
  • Cosmetics
  • E-commerce packaging

Benefits:

  • Eco-friendly
  • Easily molds to product shape
  • Cost-effective

2. Air Pillows

Inflated plastic cushions that provide excellent protection with minimal weight.

Applications:

  • Lightweight electronics
  • Small accessories or parts

Benefits:

  • Ultra-light
  • Easy to use
  • Space-saving in storage

3. Foam-in-Place

A material that expands on-site to conform precisely around the product, offering a custom protective fit.

Applications:

  • Precision instruments
  • Medical equipment

Benefits:

  • Tailored protection
  • Excellent for irregular shapes
  • Ideal for fragile and high-value items

4. Biodegradable & Sustainable Options

With increasing focus on sustainability, more businesses are choosing eco-conscious fillers, such as biodegradable packing peanuts or plant-based inflatable cushions.

 

How to Choose the Right Void Fill Material?

The optimal solution depends on several key factors:

  • Product weight and fragility
  • Shipping method and distance
  • Environmental requirements (recyclable, biodegradable)
  • Packing volume and need for automation
 

Our tip: Get in touch with our team of experts—we’ll help you find the best fit for your packaging workflow and product specifications.

 

Final Thoughts

Void fill is more than just “filler.” It’s a crucial part of secure, professional, and cost-effective packaging. By choosing the right materials, you can minimize damage, streamline your logistics, and improve your customers’ satisfaction.

Explore our full range of protective void fill materials here:  Void and loose fill | MAVA Industrial SA