Void Fill & Protective Packaging: A Practical Guide
Void fill is anything that fills the empty space around a product inside its box. Get it right and your goods arrive intact; get it wrong and even a well-chosen carton won't save them.
Why void fill matters
In transit, parcels are dropped, stacked and vibrated for hours. Any empty space lets the product move, and movement is what causes damage: items knock against the walls, rub their neighbours, and rattle loose. Void fill immobilises the contents so shocks are absorbed by the packaging, not the product.
The main options
| Material | Best for | Notes |
|---|---|---|
| Paper / kraft | General fill, cushioning, wrapping | Recyclable, versatile, tidy |
| Bubble wrap | Fragile surfaces, wrapping | Cushions and wraps in one |
| Air pillows | Filling large voids | Light, fast, low material use |
| Foam | Heavy or delicate items | Best shock absorption |
| Corner protectors | Frames, glass, electronics | Guards the weakest points |
How much clearance per side
Wrap the item, then leave cushioning between it and every wall. As a rough guide by fragility:
- Sturdy items: around 3 cm per side.
- Moderately fragile items: around 5 cm per side.
- Very fragile items (glass, ceramics): 5 cm or more, plus corner protection.
Snug beats loose
A common mistake is a small product rattling around in an oversized box padded with a handful of filler. A snug carton with thin, complete protection performs far better than a loose product in a big box — and it cuts dimensional-weight costs too. Size the box to the wrapped item, then fill the remaining gaps completely.
Ready to pack properly? Browse our boxes and protective materials, or read Packing fragile items safely for a step-by-step method. Not sure what you need? Contact us with your product and we'll advise.