Quick answer: Void fill packaging is material placed in the empty space around a product inside a carton. It stops the product moving, adds cushioning, and keeps items apart in transit. The main eco-friendly void fill options are paper void fill, honeycomb paper, shredded paper and woodwool, biodegradable packaging peanuts, and air pillows made with less or recycled plastic. The right choice depends on the product, the carton, your packing volume, and how your customer can dispose of the material.
Void fill has one main job: to stop products moving around inside a carton. When there is too much empty space, items can slide, hit the sides of the box, or knock into each other during transport.
The carton itself is just as important. A box that fits the product properly will usually need less void fill, be quicker to pack and cost less to send than an oversized carton filled with extra material.
There is no one option that works for every order. Paper suits many everyday cartons, honeycomb wrap helps protect fragile surfaces, woodwool works well in presentation packs, and air pillows are handy when weight and packing speed matter. This guide compares each type of void fill packaging, explains what makes an option genuinely more sustainable and shows how to use less material without putting products at risk.
What is void fill packaging?
Void fill packaging is any material used to fill the gap between a product and the walls of its shipping carton. Its main job is to hold the product still, so it cannot build up speed and strike the carton or other items when the parcel is dropped, tipped or stacked.
Void fill is different from protective wrap. Void fill takes up empty space, while wrap sits directly on the product to cushion it or protect the surface. Some materials, such as honeycomb paper and air bubble film, can do both jobs depending on how they are used.
Types of void fill packaging
The most common types of void fill packaging used in Australian warehouses are:
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Paper void fill: crumpled or pad-formed kraft paper, from hand-torn rolls to machine-fed systems
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Honeycomb paper packaging: die-cut kraft paper that expands into a cushioning mesh
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Wrapping paper: brown kraft rolls and white butchers paper sheets for lining, wrapping and separating
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Shredded paper and woodwool: loose fibres used in hampers and gift packs
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Biodegradable packaging peanuts: loose fill that flows around irregular shapes
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Bubble wrap: including biodegradable bubble film for full-surface cushioning
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Air pillows and air bubble film: inflated film that fills gaps with very little added weight
Why the correct void fill matters when sending parcels
A parcel can be handled many times between your packing bench and the customer's door. It may travel along conveyors, through courier depots and sorting facilities, then spend time in a delivery vehicle. During that trip, it can be dropped, bumped or moved around more than you might expect.
The right void fill holds the product in place, so it does not hit the sides of the carton or knock into other items. It also gives the product some cushioning, helping it arrive in the same condition it was in when it left your warehouse.
What you use will depend on the product, its weight, how fragile it is and how much room is left in the carton. Paper may be enough for a lighter item. Fragile, heavy or awkwardly shaped products may need honeycomb paper, air cushions, biodegradable packaging peanuts, or a mix of protective materials.
The amount matters, too. Too little leaves the product open to damage. Too much can put pressure on the content, cost more, and create waste the customer then has to deal with. Getting the carton and void fill right helps reduce damaged deliveries, returns, replacement freight and complaints.
What should void fill do?
The product should stay in place, but the carton should still close without being forced. Depending on what is being packed, the void fill may also need to absorb a knock, keep products apart or stop a finished surface from being scratched.
Before choosing a material, look at:
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How much empty space is left once the product is in the carton
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Whether the product is light, heavy, fragile or sharp-edged
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Whether several items are packed in the same carton
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How the carton will be stacked, handled and transported
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How quickly the packing bench needs to work
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How the customer can reuse, recycle or dispose of the material
Adding more void fill is not always the answer. If the carton is much larger than the product, using a better-sized box may make a bigger difference than adding more cushioning.
How to choose void fill packaging in five steps
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Measure the void. Pack the product in the carton and check how much empty space is left on each side.
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Assess the product. Note its weight, fragility, and surface finish, and whether it has sharp corners or edges.
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Check the journey. Consider the courier network, how often the parcel will be handled and whether cartons will be stacked or palletised.
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Match the material to your volume. Loose fill and hand-torn paper suit lower volumes, while machine-fed paper or air cushion systems suit busy benches.
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Test and review. Pack a sample carton, shake it and check for movement, then track damage and returns once the change is live.
Paper void fill for everyday cartons
Omni PaperFil comes in rolls, dispenser boxes and machine-fed options for busier packing benches, and you can compare the full range of PaperFil paper, machines and dispensers to suit your volumes. Our Omni PaperFil recycled paper void fillis available in 380mm x 500m rolls. We also supply heavier tri-fold paper that can be formed into stronger pads when a product needs more support.
Paper also makes sense when you want the carton and void fill to stay within the same paper-based waste stream. The customer can usually flatten it and place it in paper recycling, as long as it is clean and accepted by their local service.
Best used for: General ecommerce orders, boxed retail products, homewares, parts and mixed dispatch where products need to be held in place.
Brown and white wrapping paper
Wrapping paper can be used to protect a surface, keep products apart, or fill smaller gaps inside a carton. Omni's Australian-made brown kraft wrapping paper roll is 300mm wide, 400m long and 50gsm. It can sit on a dispenser at a busy packing bench or simply be torn by hand when volumes are lower.
White butchers paper sheets are a good option when the presentation needs to look a little cleaner. They can be used to wrap individual products, line a box or separate items before another void fill material is added. The 610mm x 810mm sheets also give the packer a consistent amount of paper each time.
Honeycomb paper packaging
Honeycomb paper is stored flat and opens up as it is pulled from the roll. The die-cut paper expands into a honeycomb pattern that grips around the product and provides cushioning. For many packing jobs, it can hold around the item without tape.
It is commonly used for bottles, glassware, ceramics, cosmetics, and other products where the surface needs protection. It can also be layered between several items in the same carton. Our honeycomb paper packaging range comes in brown, black and white, with rolls, sheets and dispenser options available. For everyday benches, the Omni brown honeycomb paper wrap comes on a 380mm x 250m roll.
Because it is made from paper, honeycomb wrap is plastic-free and can usually be recycled with the carton where the customer's local service accepts paper.
Honeycomb paper can replace bubble wrap for many products, but it still needs to provide the right level of protection. Heavy, sharp or very fragile items may also need corner, edge or impact protection.
Best used for: Bottles, glassware, ceramics, gifts and customer-facing orders where wrapping and presentation both matters.
Shredded paper and woodwool
Shredded paper and woodwool are often used in hampers, gift boxes, and presentation packaging. They fill the space around the products without hiding everything when the box is opened.
Woodwool is made from thin strands of shredded timber, so it is a plastic-free, natural void fill. Omni stocks natural woodwool in a 1.5mm cut and natural woodwool in a 3mm cut. The finer 1.5mm cut gives a softer finish, while the 3mm cut adds more bulk around larger products.
One thing to keep in mind is that loose fibres can move during transport. These options are better suited to presentation packs and lighter items than heavy products that need to be held firmly in place.
Best used for: Hampers, wine boxes, candles, cosmetics, gift packs and locally made products where presentation is important.
Biodegradable packaging peanuts
Biodegradable packaging peanuts settle around awkward shapes and fill gaps that folded paper may not reach. They are lightweight and can be useful when several fragile or irregular products are packed together.
Omni Packaging supplies biodegradable packaging peanuts in 400 litre bags. They are quick to pour, although the bags do take up space near the packing bench. The carton also needs to close properly, so the peanuts stay inside during transport.
Always check the product instructions before telling customers how to dispose of them. Biodegradable, compostable, and recyclable are not the same thing. The correct option depends on what the peanuts are made from and what facilities are available to the customer.
Best used for: Irregular products, fragile mixed orders and cartons with gaps that are difficult to fill with paper pads.
Biodegradable bubble wrap
Bubble wrap sits closely around a product and helps cushion it from knocks inside the carton. It works well when the whole surface needs protection, rather than only filling the empty space around it.
Omni's biodegradable bubble wrap range includes 10mm and 20mm bubbles in several roll and slit widths. The film contains an additive that helps it break down under certain environmental conditions. It is still plastic, so it should not be described as plastic-free or grouped in with paper-based packaging.
Before choosing it, look at the level of protection the product needs and how the customer will dispose of the film. Disposal options can differ between local councils and commercial recycling services.
Best used for: Fragile products, sharp corners and items needing a flexible cushioning layer around the full surface.
Air pillows packaging and recycled air bubble film
Air pillows packaging is a simple way to fill larger gaps without adding much weight to the carton. Air pillows are clean, quick to use and suit ecommerce orders where the main job is stopping a lightweight product from moving.
AirFil Hybrid 200mm x 120mm inflatable air pillow film comes on a 700m roll and is perforated every 120mm. One roll makes around 5,833 pillows once inflated. It runs through the AirFil Hybrid machine at speeds of up to 8 metres per minute.
For lower packing volumes, or sites without an inflator, AirFil Handypak pre-inflated air pillows come in a 400 litre pack. They take up more room than a roll of uninflated film, but there is no machine to install or operate at the bench.
AirFil Hybrid recycled air bubble film is made from 100% recycled HDPE. The 400mm x 450m roll is perforated every 330mm. Unlike air pillows, it wraps around the product, so it is useful when a lightweight cushioning layer is needed.
Air pillows and air bubble film are still plastic-based. Using less film or choosing recycled content can reduce the amount of virgin plastic used, but the film needs to stay out of paper recycling. Check whether the customer has access to a suitable soft plastic collection service before providing disposal instructions.
Best used for: Lightweight ecommerce orders, electronics, boxed products and higher-volume benches where speed and low pack weight matter.
Quick void fill comparison
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Option |
Best suited to |
Main benefit |
Consider before use |
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Paper void fill |
General cartons and mixed dispatch |
Easy to form by hand or machine |
Needs enough paper density to hold the product |
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Honeycomb paper |
Fragile surfaces, bottlesand gifts |
Wraps and cushions in one material |
May need extra protection for heavy or sharp goods |
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Shredded paper or woodwool |
Hampers and presentation packs |
Fills space and improves presentation |
Can shift and needs storage near the bench |
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Biodegradable peanuts |
Irregular shapes and hard-to-reach gaps |
Flows around mixed products |
Confirm material and disposal instructions |
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Biodegradable bubble wrap |
Fragile products and full-surface wrapping |
Flexible cushioning around the item |
Still plastic-based; check disposal route |
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Air pillows |
Lightweight ecommerce orders |
Fast, light and compact before inflation |
Not suitable for very heavy or sharp products |
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Recycled air bubble film |
Products needing light wrapping and cushioning |
Made with recycled HDPE |
Keep separate from paper recycling |
Void fill packaging by product type
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Product type |
Suggested void fill |
Why it works |
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Clothing and soft goods |
Paper void fill or air pillows |
Light products that mainly need holding in place |
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Cosmetics and skincare |
Honeycomb paper, with shredded paper for presentation |
Protects glass and pumps while the unboxing still looks considered |
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Wine, spirits and glass bottles |
Honeycomb paper, with dividers in multi-bottle cartons |
Wraps each bottle and stops bottles touching |
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Ceramics and homewares |
Honeycomb paper plus paper void fill |
Surface protection plus a firm hold for heavier pieces |
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Electronics and boxed products |
Air pillows or paper pads |
Fills gaps around a retail box with little added weight |
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Hampers and gift boxes |
Woodwool or shredded paper |
Fills space and presents products well on opening |
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Parts, tools and hardware |
Heavy tri-fold paper pads |
Dense fill that supports weight and stands up to hard edges |
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Irregular or mixed items |
Biodegradable packaging peanuts |
Flows into gaps other materials miss |
Loose fill or a void fill machine?
Loose fill works well when packing volumes are lower or the products change throughout the day. Peanuts, shredded paper, woodwool and pre-inflated pillows can be kept close to the bench and used when needed.
At higher volumes, a paper void fill or air cushion machine can save storage space and keep material ready at the packing bench. The paper or film stays flat on a roll and is only converted when the packer needs it.
A void fill machine converts flat paper or film into cushioning at the packing bench, so material is made up as it is needed rather than stored pre-formed. The Omni PaperFil paper pad cushion machine with hopper and overhead delivery is set up for benches running steady daily volumes. The overhead delivery feeds paper down to the packer, so the bench stays clear, and the hopper holds converted pads ready to pick up, which keeps the packer working rather than waiting on the machine.
When weighing up the two options, look at more than the cost of the material. Think about storage space, how often the bench needs refilling, where the machine will sit, access to power, and how many cartons are packed during the busiest part of the day.
Which void fill packaging is the most eco-friendly?
There is no single most eco-friendly void fill for every business. The most sustainable option is the one that protects the product with the least material and suits the disposal options for your customers actually have. For many ecommerce orders, paper void fill is a strong starting point because it is plastic-free and can usually be recycled with the carton.
Be clear about what makes a void fill option more environmentally responsible. Paper may be recyclable and plastic-free. An air pillow may use less material or be made with recycled plastic. A biodegradable product may only break down under certain conditions. These are different benefits, and they should be explained properly.
|
Material |
Plastic-free? |
Typical end of life (check local rules) |
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Paper void fill and wrapping paper |
Yes |
Kerbside paper and cardboard recycling where accepted |
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Honeycomb paper |
Yes |
Kerbside paper recycling where accepted |
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Woodwool |
Yes |
Reuse, or green waste or compost where local rules allow |
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Shredded paper |
Yes |
Reuse, or recycling where the council accepts shredded paper |
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Biodegradable packaging peanuts |
Depends on material |
Follow the product's disposal instructions |
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Biodegradable bubble wrap |
No |
Keep out of paper recycling and check local options |
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Air pillows and recycled air bubble film |
No |
Reuse, or a soft plastic collection service where available |
Product protection still comes first. From there, compare how much material is used, whether it contains recycled content, how it will be disposed of, how much room it takes to store and how quickly the team can pack with it. A damaged product and a replacement delivery will usually create more waste than using the right amount of protection the first time. Getting your environmental claims right If you tell customers your packaging is sustainable, the claim needs to be accurate and specific. The ACCC has published guidance for businesses on making environmental claims, and broad terms such as eco-friendly or green can mislead if they are not backed up. Say what the material is and what the customer should do with it, for example "plastic-free paper void fill, please place in your paper recycling", rather than relying on a general green label.
How to use less void fill
The first place to look is the carton. If the box is too large, the packing team has to add more material just to stop the product moving. Our guide on how to get your cardboard packaging right the first time covers carton selection in more detail.
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Use the smallest carton that leaves enough room for the protection the product needs
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Keep a sensible range of carton sizes rather than forcing every order into the same box
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Place heavier products at the bottom and stop them shifting before adding lighter items
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Use dividers or wraps between products instead of filling the entire carton with loose material
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Test the packed carton by moving it gently and checking for product movement
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Review damaged deliveries and adjust the carton, protection or packing method where needed
This is not about removing protection that the product actually needs. It is about using the right material and not filling empty space that could have been avoided with a better-sized carton.
Common void fill mistakes to avoid
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Overfilling: a bulging carton weakens the tape seal and reduces stacking strength
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Underfilling: if the product moves when the closed carton is shaken, it can be damaged in transit
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Loose fill under heavy items: heavy products sink through loose fill and end up resting on the base of the carton
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Mixing paper and plastic in one carton: it makes recycling harder for the customer
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Vague green claims: customers need to know what the material is and how to dispose of it
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Choosing on unit price alone: storage space, packing time and damage rates all add to the real cost
Find the right void fill packaging for your cartons
Omni Packaging supplies paper void fill, honeycomb wrap, woodwool, biodegradable packaging peanuts, bubble wrap and AirFil products. Browse the full void fill packaging range, or talk to our team. We can look at the product, packing setup and daily volume and help narrow down the options.
Speak to a void fill specialist
If you are not sure which void fill suits your products, the fastest way to narrow it down is to have someone look at the carton, the product and your daily volumes together. The right answer usually depends on details that are difficult to judge from a product page: how much room is left once the product is in the box, how the parcel is handled in transit, how much space there is at the bench and how many cartons go out on your busiest day.
It is also worth testing before committing one material across every order. Packing a few cartons with a sample and checking for movement will tell you more than comparing specifications.
Contact the Omni Packaging team to talk through your packing setup, ask about samples, or get a recommendation based on your cartons and volumes.
Frequently asked questions
What is void fill packaging?
Void fill packaging is material placed in the empty space around a product inside a carton. Its main job is to stop the product moving, although it can also add cushioning, keep items apart, and protect surfaces during storage and transport.
What is the most eco-friendly void fill?
There is no single answer because every product and packing setup is different. Paper void fill is often a good choice when the customer can place it in paper recycling. Air pillows use a small amount of lightweight film, while recycled-content film reduces the amount of virgin plastic used. The best option is the one that protects the product properly without using more material than needed.
Is paper void fill recyclable?
Paper void fill can usually go into kerbside paper and cardboard recycling, as long as it is clean, dry and accepted by the customer's local council. Keeping paper void fill separate from plastic materials in the same carton makes it easier for the customer to recycle.
Is honeycomb paper a replacement for bubble wrap?
For many bottles, glassware, ceramics and gift products, yes. Very fragile, heavy or sharp items may still need extra protection. It is worth packing and testing a carton before making the change across every order.
Can packaging machinery reduce packaging waste?
It can, when the machine converts material on demand at the bench. The packer makes up only what each carton needs, rather than reaching for a pre-formed pad or an oversized handful, and the material is stored flat until it is used. Machines running paper or recycled-content film also keep the void fill in the same waste stream as the carton. Our eco-friendly packaging machinery range covers this equipment. The saving comes from using less material per carton, so it is worth checking daily carton volumes before committing to a machine.
What is the best void fill for fragile items?
Honeycomb paper is a strong choice for glass, ceramics and bottles because it wraps and cushions in one material. Very fragile or heavy items may need a combination, such as honeycomb wrap around the product with paper void fill or air pillows holding it in the centre of the carton.
What is the difference between void fill and protective wrap?
Void fill takes up the empty space around a product. Protective wrap sits directly around the item to cushion it or protect the surface. Some materials, such as honeycomb paper and air bubble film, can do both depending on how they are used.
Are air pillows eco-friendly?
Air pillows use a small amount of lightweight film and take up very little room before they are inflated. Recycled-content film can also reduce the amount of virgin plastic used. They are still plastic based, so customers will need access to a suitable soft plastic collection service if the film is to be recycled.
Are biodegradable packaging peanuts compostable?
Not always. Biodegradable, compostable and recyclable mean different things. Whether packaging peanuts can be composted depends on the material they are made from, so follow the disposal instructions for the product before advising customers.
What is the difference between a biodegradable bubble wrap and a recycled bubble film?
Biodegradable bubble wrap contains an additive that helps the film break down under certain conditions. Recycled air bubble film is made from recycled plastic, such as the 100% recycled HDPE used in AirFil Hybrid film. Both are still plastic and should be kept out of paper recycling.
How much void fill do I need?
Use enough that the product cannot move when the closed carton is shaken, but not so much that the carton bulges. Leave a cushioning gap on every side of the product, fill it evenly, then test the packed carton before rolling the method out.
When should I use a void fill machine?
A machine is worth looking at when ready-made void fill is taking up too much room or slowing the packing bench down. Look at the number of cartons packed during peak periods, the space available and whether paper or air cushioning is right for the products being sent
