Void Fill Solutions: How to Choose the Best Option for Your Products

Whether you ship domestically or globally, void fill is an essential component of your packaging process. Choosing the right void fill to protect your products isn’t just about filling empty space, though, it’s about keeping your products safe and your packaging process efficient. 

Here are a few key factors to think about when selecting the best void fill for your business:

• Cushioning and Protection: How well the void fill cushions items and retains its protective properties is essential. Fragile items need extra cushioning, while sturdier products may only need basic protection.  
• Ease of Integration: Think about how easy it is to integrate the void fill product into your dispensers and packing process. Some void fills are quicker and easier to work with than others, which is especially important as your business grows.
• Sustainability and Disposability: This factor is becoming more important with consumers. Eco-friendly void fill options like recyclable or biodegradable materials can help reduce waste while still offering solid protection.

HexaFil from HexcelPack ticks all three of these boxes, making it a great choice for businesses of all sizes, from small Etsy sellers to big enterprises. 

Cushioning and Protection 

When shipping products, you want to ensure they arrive in good condition. Void fill’s primary purpose is to protect items during shipping and storage by filling the empty spaces in a box, preventing movement, and cushioning the product to absorb shock. This helps prevent damage like rubbing, cracking, or breaking. Without it, you risk dissatisfied customers, negative reviews, and an increased rate of returns and exchanges. These additional costs—postage, extra labor, and lost merchandise—directly impact your profit margins.

Choosing the right void fill can be the difference between satisfied and dissatisfied customers. Void fill comes in various shapes, sizes, and materials, including air pillows, plastic bubble, and foam peanuts. 

One void fill product that’s gaining popularity in the packaging industry is HexaFil™, a paper-based void fill. 

HexaFil offers superior cushioning thanks to its innovative design. It starts with slit-sheet paper, dispensed in a spiral formation, creating a bulky void fill that protects while retaining its shape, never flattening out. If product movement is a concern, HexaFil can be paired with HexcelWrap™ product wrap for added stabilization and packaging strength. We’ll cover packing systems and processes in more detail below.

HexaFil is trusted across many industries, including:

• Aerospace and automotive
• Medical and pharmaceutical
• Health and beauty
• Manufacturing and industrial
• Retail and e-commerce
• Art and handicrafts

Its unique design makes HexaFil more efficient than many alternatives, letting you use less fill for the same level of protection. This saves both time and money in the long run.

Want your boxes to look great when your customers unpack them? With HexaFil’s exceptional cushioning, your products will arrive in pristine condition. HexaFil comes in two colors–natural and white–allowing you to match the packaging to your brand for a stunning unboxing experience. This is especially valuable in today’s market, where influencers and social media often influence purchasing decisions.

Ease of Integration 

A void fill product needs to work seamlessly with your entire packaging process, including your dispensing systems. It should be versatile enough to use with both manual and automated dispensers, and simple enough for employees or seasonal help to operate. Ideally, you want a void fill that anyone can grab for a quick packing job, even if they’re not regularly in that department.

HexaFil delivers that versatility and ease of use. It’s compatible with both manual and automatic dispensers, making it a great choice for businesses of all sizes.

HexcelPack offers several dispensing options for HexaFil, giving you the flexibility you need:

• Manual HexaFil™: This easy-to-use manual dispenser requires no maintenance or electrical power. Available in mobile and fixed units for packing tables, it’s quick to load and has no wearing parts, so you can dispense exactly how you like.  
• HexaFil™ Fil in a Box™: For an eco-friendly, intuitive dispensing solution, this sturdy, recyclable box is perfect for daily use. Simply open the box, remove the paper core, feed the paper through the opening, close the lid, and it’s ready to use. 
• Auto HexaFil™: This hands-free, automated dispenser is ideal for speed and efficiency in high-volume packing environments. It consistently dispenses void fill from a machine that’s easy to load and program, with push-button controls on top. A foot pedal lets users start and stop dispensing as needed. Plus, it features a cut-to-length option, allowing you to preset the exact length of material and easily adjust for different product sizes, providing even more flexibility for your packing process.

HexcelPack also provides customized dispensing solutions for businesses of all sizes across a wide variety of industries. Contact us for an assessment of your current packing process so we can help you boost efficiency and streamline operations.

Sustainability and Disposability 

Many traditional packing materials, like plastic bubble, are harmful to the environment. They end up in landfills or oceans and take decades to biodegrade. 

Even if a plastic-based void fill claims to be recyclable, it may not be practical for your customers. Some bubble products can technically be recycled, but only at specialized facilities not easily accessible to the average consumer. That’s why void fill products that can be directly recycled–like HexaFil–are so beneficial. Customers can simply place HexaFil in their curbside recycling, where it’s processed alongside paper and cardboard products, helping reduce waste and pollution. They can also choose to compost HexaFil if they prefer.

There are many other benefits to choosing sustainable packing products including:

• Eco-Friendly Manufacturing: Sustainable packaging is made using recycled or renewable materials, designed to produce the lowest carbon footprint possible. Reducing industrial waste and greenhouse gases is better for the planet and the air we breathe.
• Safe Handling: Sustainable packing products, including HexaFil, are safer to handle since they don’t contain toxic materials like plastics that may leach harmful chemicals. This is important for both your customers and your employees who regularly handle packing materials.
• Efficiency: Many sustainable packing products, including HexaFil, are more efficient, allowing you to use less material with every box you pack. This reduces both material usage and labor costs.
• International Compliance: If you ship merchandise internationally, note that many European countries will require sustainable packaging by 2030. Get ahead of the curve now to remain competitive in the market.
• Consumer Demand: Sustainability is increasingly important to consumers. Many, especially younger Millennial and Gen Z demographics, are willing to pay more for eco-friendly packaging. Customers who value energy-efficient or water-saving products for their homes want packaging that reflects those same values.

Choose HexaFil for Your Void Fill 

With over 30 years of experience, HexcelPack provides sustainable wraps, void fill, and mailers trusted by businesses worldwide. We’re proud to partner with the top three U.S. retailers, delivering reliable, eco-friendly packaging solutions. When it comes to choosing the best void fill solution for your business, HexaFil should be at the top of your list. 

To get started, browse our selection of sustainable packaging materials in our shop or reach out to our team with any questions.