Void Fill Products & Solutions

The most common void fill types are air pillows, paper fill, bubble wrap, packing peanuts, Instapak foam, and heavy-duty bubble. Air pillows are lightweight and low-cost per shipment; paper fill is recyclable and useful for wrapping and filling; bubble wrap cushions fragile items; packing peanuts work well for irregular shapes; Instapak foam custom-conforms around high-value items; and heavy-duty bubble is used for heavier or industrial products.

Yes. Automated void fill systems, such as air pillow machines and paper fill dispensers, connect directly to packing stations and produce material on demand. Automation reduces material overuse, lowers cost-per-package, and improves packing consistency. It is especially effective for mid-to-high volume e-commerce and distribution operations.

The right void fill depends on product fragility, package weight, and volume throughput. Fragile or high-value items benefit from Instapak foam or bubble wrap. Lightweight e-commerce orders are well-suited to air pillows or paper fill. High-volume operations should consider automated void fill systems to reduce material waste and labour time.

Air pillows are better for filling large empty spaces quickly and cost-efficiently, and they take up far less storage space because they arrive as flat film and are inflated on demand. Bubble wrap provides stronger surface-level cushioning and is better suited for wrapping individual items directly. Many operations use both: bubble wrap around the product and air pillows to fill the remaining void.