In the first part of this series, I described five general types of void fill –

1. Loose fill materials
2. Industrial papers
3. Flexible foams and bubble material
4. Expandable foam
5. Inflatable air pillows

Now let’s look at the qualities you may need from your void fill material, and see how the various options stack up.

Surface protection. For glass, metal, and scratch-sensitive plastics, polypropylene (PP) foams are the least abrasive option, followed by polyethylene (PE) foams and bubble. Industrial papers, depending on the grade, may also work.

Dust free. Loose fill, whether polystyrene or one of the various biodegradable varieties, are prone to flaking. Industrial papers sometimes contain dust as a result of the trimming process. For shipping things such as pharmaceutical or personal health care products, look in other directions for void fill. (more…)

The best thing about void fill is there are so many options. The worst thing about void fill is … there are so many options. Selecting the right void fill material is difficult — keeping a few things in mind will help you make the right decision.

Void fill can be broken down into several categories.

Loose fill materials, commonly called “packing peanuts”, are made from a variety of eco friendly and not so eco friendly materials, including polystyrene, corn starch, and paper. The weight of loose fill varies depending on the material, but generally speaking, loose fill is inexpensive per application, but messy and not very effective for cushioning.

Industrial papers include kraft paper, newsprint, and tissue paper. Most papers used for void fill have high PCW content, are fairly inexpensive per application, and are easier and cleaner to use than loose fill. Industrial papers are available in sheeted or roll form, making them easy to integrate into most packing operations. Multi-layered papers have become more popular in recent years, mainly due to shippers looking for alternatives to plastic-based packing materials. Multi-layer papers, which are typically made on-site, provide excellent cushioning, but are significantly heavier than plastic alternatives. (more…)

Some types of secondary packaging material are far worse for the environment than others. One of the worst, in our opinion, is the old standby for void fill, polystyrene loose fill. Folks who use this material because of its (perceived) low cost and (real) speed, are, well … ecoblivious.

Polystyrene is recyclable, but not easily so. The material is extremely lightweight and therefore expensive to ship to recycling centers, which are often a long distance away. While associated transportation costs have always been high, the economics are now even worse due to the rapid run up in fuel costs. (more…)