Void fill is one of the most misunderstood parts of packaging.
Most businesses know they need “something” to fill space. But the choice between paper, air, or foam is often based on habit rather than performance.
The truth is: there’s no single best option. What works depends entirely on how your product behaves in transit and how your operation runs.
This guide breaks down the differences and, more importantly, when each one actually works.
Before comparing materials, it’s important to understand the role of void fill.
Void fill exists to:
If a product is moving, dropping, or shifting. Void fill isn’t doing its job.
The goal isn’t to “fill space.”
It’s to create stability under pressure.
Paper-based void fill is one of the most widely used options in eCommerce and fulfilment.
Where paper works best:
Why it works:
Paper is particularly effective when the goal is to stop movement, not just cushion impact.
Where it can fall short:
Air cushions are commonly used for fast-paced packing environments.
Where air works best:
Why it works:
Where it can fall short:
Air works best when speed is key — but it shouldn’t be relied on to stabilise heavier or fragile products.
Foam solutions are typically used for higher-risk shipments.
Where foam works best:
Why it works:
Where it can fall short:
Foam is less about speed or efficiency and more about risk reduction.
The most effective packaging setups don’t rely on one material — they use the right combination.
Most void fill problems come from misuse, not material choice.
| Packaging Setup | Best For | Key Benefit |
|---|---|---|
| Paper + Air | General eCommerce and fulfilment operations | Paper stabilises products while air cushions fill remaining space efficiently |
| Paper + Foam | Fragile or high-value items | Paper provides structure while foam delivers enhanced impact protection |
| Air + Internal Wrap | Lightweight products in larger boxes | Air fills excess space quickly while internal wrap protects the product |
| Paper Only | Mixed or irregular products | Creates structure and reduces movement during transit |
| Foam Only | Delicate products requiring maximum protection | Offers superior shock absorption and damage prevention |
| Packaging Objective | Why It Matters |
|---|---|
| Product Stability | Prevents movement and helps reduce transit damage |
| Packing Consistency | Creates a repeatable process across packing teams |
| Operational Efficiency | Supports faster packing times and efficient material use |
Void fill isn’t about preference — it’s about performance.
Paper, air, and foam all have a place, but they solve different problems.
The key is understanding what your product needs:
When the right material is matched to the right situation, packaging becomes simpler, more consistent, and more effective.
Void fill is one of the most misunderstood parts of packaging. Most businesses know they need “something” to fill space. But the choice between paper,
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