Choosing the Right Void Fillers for Packaging

What Are Void Fillers?

Void fillers are inner packaging materials used to protect items by limiting internal shift, absorbing minor impacts, and preventing surface abrasion or breakage.

In the absence of appropriate void filling, products are susceptible to damage caused by impact, vibration, or friction—especially items that are fragile, irregularly shaped, or lightweight. Even minimal movement can result in functional or cosmetic defects.

Beyond protection, void fillers also contribute to presentation. By holding items securely in place, they support a clean and organized unboxing experience, which is increasingly relevant in consumer-facing sectors.

Typical applications include:

• E-commerce and retail: Filling voids in boxes containing apparel, cosmetics, electronics, or books.
• Electronics and appliances: Using foam or molded inserts to protect sensitive components and glass elements.
• Glassware and ceramics: Applying paper-based or air-filled materials for cushioning.
• Automotive and industrial parts: Stabilizing metal components to prevent surface damage or impact during transit.
• Luxury goods: Enhancing appearance and fit with custom die-cut inserts or decorative paper fillers.

Types of Void Fillers

Below are commonly used types across various sectors:

Key Factors to Consider When Choosing Void Fillers

Selecting an appropriate void filler requires balancing protection, cost-efficiency, operational requirements, and customer perception. The following factors should inform the selection process:

• Product Size, Fragility, and Weight: Items that are heavy, fragile, or have irregular shapes demand void fillers with higher cushioning performance and structural support. In contrast, lightweight or durable products may only need minimal material to restrict movement.
• Box Dimensions Relative to Product Size: Excess space within packaging increases the risk of internal movement and typically requires more filler. Right-sizing outer packaging can reduce material use and improve overall packing efficiency.
• Shipping Method and Handling Environment: Products subjected to extended transit, multiple handovers, or high-impact conditions (such as air freight or parcel sorting facilities) require more resilient void fillers. Key considerations include vibration resistance, stacking pressure, and exposure to temperature or humidity variations.
• Cost and Packing Efficiency: Void fillers vary significantly in unit cost, application time, and storage demands. While low-cost options may appear economical, they can slow down packing lines or require more volume. Evaluate material costs alongside labor, throughput speed, and warehouse space.
• Environmental Impact and Brand Positioning: Sustainability has become a determining factor for many businesses. Recyclable, compostable, or biodegradable materials align with environmental goals and consumer expectations. Material transparency and end-of-life considerations should be part of procurement decisions.
• Customer Experience and Brand Presentation: Void fillers contribute to perceived product value. Neatly arranged paper, molded inserts, or custom fillers can reinforce brand identity, while disorganized or excessive plastic may detract from the unboxing experience. The choice of filler should reflect the intended brand image and customer touchpoints.

Balancing Protection, Cost, and Sustainability

Effective void filler selection requires navigating trade-offs between material performance, cost-efficiency, and environmental impact.

The goal is to achieve adequate product protection while minimizing resource use and aligning with sustainability targets.