Void fillers protect goods during storage and shipment by occupying empty spaces within a package. These packaging solutions help prevent product damage and enhance presentation by minimising internal movement and absorbing shocks.
Void fillers enhance packaging performance by enhancing product protection and load stability and supporting efficient logistics. In distribution environments, where shipping volumes are high and margins for error are narrow, void fillers help reduce damage rates and lower return-related costs.
What Are Void Fillers?
Void fillers are packaging materials inserted into packaging to fill empty spaces around a product. Their primary function is to limit movement within the container, preventing potential damage caused by shocks, vibrations, or compressive forces during transit.
Available in various formats, void fillers are selected based on the shipped items’ size, weight, fragility, and sustainability requirements.
Common Types of Void Fillers
Void fillers are selected based on product fragility, packaging format, handling conditions, and environmental considerations. The following are widely used in diverse packaging operations:
Key Benefits of Using Void Fillers
Void fillers contribute to both product integrity and operational efficiency. Their strategic use across packaging systems supports multiple performance goals.
- Protection Against Impact and Vibration: Void fillers absorb shocks and dampen vibrations during handling, transportation, and distribution.
- Prevention of Product Movement: Void fillers stabilise items by eliminating space and maintaining consistent positioning regardless of box orientation.
- Minimising Damage During Transit: By securing products and absorbing external forces, void fillers reduce the incidence of transit-related damage.
- Enhancing Customer Unboxing Experience: Void fillers can improve presentation by keeping items neatly arranged and undisturbed during delivery. Clean, organised internal packaging contributes to a positive brand perception.
- Reducing Returns and Product Loss: Damaged shipments lead to increased return rates and inventory loss.
Choosing the Right Void Filler
Selecting an appropriate void filler requires alignment between protective performance, packaging efficiency, and material sustainability. The optimal solution depends on product characteristics, handling conditions, and operational priorities.
The weight and fragility of the product are primary determinants when evaluating void filler options. Heavier items may require denser materials like moulded inserts or foam, while lightweight, non-fragile goods can be secured with paper or air pillows. Cost considerations extend beyond material price, including storage, labour, automation compatibility, and shipping dimensional weight.
Custom inserts—whether moulded pulp, foam, or die-cut corrugated board—offer tailored protection for items with unique shapes or surface sensitivities. These solutions enhance product stability and minimise the need for secondary packaging. Customisation is especially effective for reducing movement during transit and improving visual consistency in presentation-sensitive categories.
Environmental Considerations
As sustainability becomes a core priority in packaging decisions, the environmental impact of void fillers is receiving increased attention. Companies reevaluate material choices to align with recycling infrastructure, consumer expectations, and regulatory requirements.
Void fillers made from recyclable paper, moulded pulp, and compostable starch-based materials offer reduced environmental impact compared to conventional plastic-based solutions.
These alternatives are compatible with municipal recycling or composting infrastructure, contributing to more circular packaging systems. Paper-based and moulded fibre fillers are commonly selected for applications requiring easy post-consumer disposal.
Case Examples and Applications
Void fillers are deployed across industries to address specific shipping challenges and performance requirements. The following examples highlight practical applications based on product type, distribution model, and transit conditions.
Example: Electronics Packaging
Consumer electronics, circuit boards, and precision instruments require advanced cushioning to protect against static discharge, vibration, and impact: moulded foam inserts and anti-static air cushions commonly secure components within rigid cartons. Sometimes, void fillers are paired with tamper-evident or moisture-resistant outer layers to meet regulatory and quality standards in high-value shipments.
Example: E-Commerce Product Fulfilment
High-volume e-commerce operations often rely on paper-based void fillers or on-demand inflatable packaging for flexibility and speed. These solutions support variable product sizes while reducing storage space for packing materials. Paper void fill is frequently selected for apparel, accessories, and home goods due to its recyclability and consumer-friendly unboxing experience.
Example: Export Shipping and Bulk Transport
Export shipments and industrial B2B logistics often involve larger, heavier items subject to extended transit times and multiple handling points. Corrugated inserts, dense foam blocks, or moulded pulp solutions immobilise products within crates or pallets. These fillers are engineered to resist compression, absorb shock from loading equipment, and ensure cargo integrity across long-distance freight routes.
Conclusion
Void fillers are a foundational element in protective packaging, offering measurable benefits in product security, shipping efficiency, and sustainability alignment. From lightweight e-commerce parcels to high-value industrial shipments, selecting the right void filler involves careful consideration of material performance, product characteristics, and operational goals.
Stream Peak offers a comprehensive range of void-fill packaging solutions to support diverse protective packaging needs. Technical training and consultation services are also provided to ensure optimal implementation. Contact our packaging engineering team to explore tailored solutions for your specific application.
