Packaging Reference Library · Technical Reference

Void Fill Options

Void fill keeps a product from moving inside the box. Loose fill, paper, air pillows and crinkle paper all fill space, and the fairest way to compare them is cost per cubic foot of space filled.

Ref PK-0121

Draft, open for review. Check every value against the governing standard and the manufacturer’s data before use.

What it is

Void fill takes up the empty space between the product and the box so items do not shift, rub or crash into the walls. It is not the same as cushioning. A fragile item may need a cushion around it and void fill around that. Choosing the right box size first reduces how much void fill is needed.

How to identify

Loose fill (packing peanuts): expanded polystyrene or starch-based pieces, poured from a hopper or bag. Starch peanuts dissolve in water.
Paper: kraft paper crumpled by hand or by a dispenser into pads. Some systems make dense coils for heavier items.
Air pillows: small inflated film bags made on a machine from rolls.
Crinkle paper and shred: decorative cut paper, used for gifts and presentation.

Void fill compared

Option	Storage space	Speed	Mess	Recyclability	Typical use
Loose fill	Large, bulky bags	Fast pour	Can spill and cling	Reusable; foam is hard to recycle curbside	Odd shapes, mixed orders
Kraft paper	Small rolls or fanfold	Fast with a dispenser	Low	Curbside recyclable	General e-commerce, heavier items
Air pillows	Very small rolls	Fast with a machine	Low	Film recycling drop-off	Light items, high volume
Crinkle paper	Moderate	Slow, by hand	Some	Recyclable paper	Gift and retail presentation

Cost per cube

To compare options, work out what each costs to fill one cubic foot:

Cost per cubic foot = cost of the material for a case or roll / cubic feet it fills.
Add any machine lease or equipment cost spread over the expected volume.
Count labor time per pack and floor space for storage.
Count dimensional weight. A box that is larger than needed costs freight even if the void fill is cheap.

Key points

Right-size the box first. Less empty space means less fill and lower freight.
Fill the box so the product cannot move when the box is shaken, but do not overstuff so the flaps bulge.
Starch peanuts are a good fit where customers expect easy disposal, but they attract moisture.
Paper dispensers and air pillow machines take up bench space. See the packing station layout chart.

Common mistakes

Using void fill alone for fragile items.
Comparing void fill by price per bag or roll instead of per cubic foot filled.
Underfilling so the product slides to one end.
Ignoring customer complaints about loose fill mess.

Governing standards: No single product standard. Carrier packaging guidelines and ISTA test procedures for package performance.

Reference only. Verify against the current governing code or standard, the manufacturer's data and the project documents before use. Apps for Distributors disclaims liability arising from reliance on this reference.

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