How Does Void Fill Work? | HexcelPack

When shipping products, protecting them from damage is a top priority. That’s where void fill comes in. But what exactly is void fill, and how does it work?

Void fill refers to the packing materials used to fill empty spaces inside a shipping box. These materials cushion the product, preventing it from shifting during transit and reducing the risk of damage. This is especially important for fragile items like artwork, cosmetics, glassware, and electronics, which require extra protection.

In this blog, we’ll explain the purpose of void fill, highlight common types, and explore sustainable options for your business.

What Is the Purpose of Void Fill?

Using the right void fill materials provides several benefits for your business.

Protecting Items from Damage

Void fill provides essential cushioning, keeping items from shifting and bumping into each other during transit. Without it, products may arrive broken, dented, or scuffed, leading to unhappy customers and costly replacements. Void fill also acts as a buffer against rough handling during shipping—packages are often dropped, tossed, or stacked carelessly. High-quality void fill ensures your items arrive intact and undamaged.

Reducing Returns

Damaged products lead to costly returns. By properly securing items with void fill, you can significantly reduce the chances of products arriving broken, lowering return rates and improving overall customer satisfaction. When your products arrive well-protected, it means fewer complaints, less waste, and a stronger reputation for your brand.

Maintaining Product Presentation

No one wants to receive a damaged or scuffed item. Void fill prevents smaller interior boxes from rubbing against each other, maintaining the pristine appearance of your products. This is particularly important for items that are being gifted, where presentation matters most.

Similarly, influencers showcasing your products online will appreciate how well-protected and visually appealing the items are when unboxing. Positive social media publicity can enhance your brand image, especially when your products are delivered in perfect condition.

Common Types of Void Fill

While all void fill materials serve the same basic function, some are more environmentally friendly than others. Here’s a breakdown of the most common options:

• Bubble Wrap: Made from low-density polyethylene (LDPE), bubble wrap features air-filled pockets that provide cushioning and shock absorption
• Packing Peanuts: These lightweight foam pieces fill empty spaces in a package to prevent shifting. They come in traditional polystyrene foam (EPS) or biodegradable options made from cornstarch, which dissolve in water.
• Air Pillows: Inflatable plastic pouches filled with air, air pillows are commonly made from flexible plastic film, high-density polyethylene (HDPE), or low-density polyethylene (LDPE). They provide lightweight protection and are often used to fill larger voids in shipping boxes.
• Foam Inserts: Designed for precision protection, foam inserts are pre-cut or custom-molded to secure items in place. They’re typically made from polyethylene (PE) foam, polyurethane (PU) foam, or expanded polystyrene (EPS).
• Kraft Paper: A durable brown paper material that can be wrapped around items or crumpled for cushioning, kraft paper provides moderate protection and is a recyclable, biodegradable alternative to plastic-based void fill.
• HexaFil™: Made from 100% PEFC-certified Canadian paper, HexaFil is a fully recyclable, eco-friendly alternative to plastic fillers. It dispenses in a spiral formation, offering effective protection while reducing waste.

A Sustainable Alternative to Void Fill: HexaFil

If sustainability is important to your business (and it should be with new packaging regulations in place), consider opting for kraft paper or HexaFil. Most traditional plastics and foams are not curbside recyclable and often contribute to landfill waste.

HexaFil stands out as an eco-friendly solution because it’s made from 100% PEFC-certified Canadian paper and is fully recyclable. Additional benefits of HexaFil include:

• Enhanced Stability: HexaFil is designed for versatility, working seamlessly on its own or alongside HexcelWrap™. While HexcelWrap serves as the product wrap, HexaFil acts as the void fill. Used together, they complement each other by interlocking, providing enhanced stability for the package.
• Flexibility: HexaFil integrates seamlessly into any packing environment, whether you're using our retail manual dispenser, Fil-in-a-Box™, or the AutoHexaFil™ automatic dispenser for industrial applications.
• Ease of Use: Our manual dispenser for HexaFil is easy to tear by hand, speeding up your packing workflow and eliminating the need for extra tools or equipment, enhancing overall operational efficiency.
• Cost Savings: HexaFil’s cut-to-length feature, available with the AutoHexaFil dispenser, reduces waste by allowing you to preset the exact length of material needed for each package. With push-button and foot pedal controls, you can easily adjust the length, while three programmable settings ensure consistent and accurate cuts every time. This functionality minimizes excess material usage, helping to optimize your packing process and reduce waste, making it a more sustainable solution for your business.
• Aesthetic Options: HexaFil is available in two color options–white and natural to suit your brand’s look.

HexaFil is perfect for industries such as aerospace, automotive, pharmaceuticals, and retail. Whether you're a small business or a large enterprise, HexaFil can scale with your growth.

Why Choose Sustainable Packaging?

Sustainable packaging is no longer a luxury—it’s a necessity. Research shows that over half of consumers are willing to pay more for products shipped in sustainable packaging. This trend is particularly true for Gen Z and Millennial shoppers, who are more likely to gravitate toward brands that prioritize sustainability. In fact, 54% of Gen Z consumers say they actively avoid brands that don’t offer eco-friendly packaging.

Sustainable packaging is especially important in regions like Europe and Australia, where packaging regulations are becoming stricter. In Europe, for example, the European Union's Packaging and Packaging Waste Directive is driving businesses to reduce the environmental impact of packaging. Australia is following suit with its National Packaging Targets, aiming to have 100% of packaging recyclable or compostable by 2025.

Adopting sustainable packaging practices can help attract environmentally-conscious customers while aligning your business with global regulatory trends.

Additional Cost Savings with Sustainable Packaging

There are other cost savings associated with using sustainable packaging like HexaFil, such as:

• Lower Shipping Costs: Sustainable void fill materials are often lighter than alternatives, potentially reducing freight costs.
• Operational Efficiency: The quick dispensing and easy handling of HexaFil reduces time spent on packaging.
• Incentives: Some states and countries offer rebates or grants for businesses that use sustainable packaging.

Sustainable Packaging Solutions from HexcelPack

HexcelPack offers a variety of sustainable packaging solutions, including HexcelWrap, Hexcel’Ope, and HexcelStretch. These products are widely known in the packaging industry and can be used independently or synergistically together to protect nearly everything.

Beyond providing sustainable packaging products, HexcelPack offers manual, automated, and custom dispensing solutions. Our products and services help businesses streamline packaging operations while protecting both their items and the planet.

For more information about our products or dispensers, contact us today and discover how HexcelPack can improve your packaging efficiency and sustainability.