A Guide to Bubble Wrap Packaging and Void Fill Packaging
Proper protection is essential when packaging items for transit, especially for fragile or valuable freight. When shipped items get damaged due to movement or external impact that occurs throughout the logistics process, it can affect your bottom line and hurt your brand. Establishing the right protective packaging protocols for your inventory requires understanding when and how to use two of the main categories of materials: bubble wrap and void fill.
This guide explains the distinct roles these solutions play, ensuring your goods remain secure from the warehouse floor to the customer's door. We will explore selection of the right options from our range, and best-practice methods for applying them separately (or in combination) to achieve the optimal cushioning to make your packing lines more efficient and effective.
What is void fill packaging?
To determine the best strategy for your despatch team, we must first define the category. Effectively, void fill packaging is any material used to fill the empty space (the "void") inside boxes or cartons.
In modern warehouses, especially high-volume operations, smaller items are frequently packed in oversized shipping boxes. This often happens due to a mix of system-driven choices and limited box inventory, but it is primarily done for packing efficiency. Standardising a few box sizes allows for smoother warehouse handling, as very small items can easily get lost or fall through automated conveyor belts. Uniform boxes also make it easier to "play truck Tetris," stacking cartons densely for more cost-effective shipping.
Void fill packaging is designed to occupy this necessary extra size, blocking the items securely in place to prevent them from shifting during transit. This is particularly critical for sensitive objects like electronics, where even minor movement within the box can lead to internal component damage.
Common void fill options include:
|
|
|
Why is Bubble Wrap Good for Packaging?
While void fill is concerned with space, bubble wrap packaging is designed specifically for cushioning. It consists of a plastic film with air-filled bubbles that absorb shock and protect surfaces from impact.
It provides a protective layer that is wrapped directly around items. This is perfect for fragile goods such as lighting, mirrors, electronics, ceramics or intricate decorative objects. Unlike loose fill, which can shift over time in transit, a seal made with bubble wrap and tape remains fixed to the product.
Small vs Large Bubble Size
|
At Azapak, we offer a comprehensive range of bubble wrap rolls to suit diverse packaging needs.
|
 |
Foam Backed Bubble Film: Bubble wrap with an added polyfoam layer for enhanced surface protection.
Explore our full bubble film range here.
Key Differences: Bubble Wrap vs Void Fill
| Feature | Bubble Wrap Packaging | Void Fill Packaging |
| Primary Function | Cushioning and surface protection | Filling empty space and blocking movement |
| Application | Wrapped directly around the product | Poured or stuffed into the boxes |
| Best For | Fragile, breakable, or sensitive items | Non-fragile items in oversized boxes |
When to Use Bubble Wrap Packaging
Bubble wrap is the preferred choice when your packaging needs involve shielding delicate surfaces or high-precision components that cannot withstand direct impact or abrasion. Because it is designed to absorb shock through its air-filled structure, it acts as a perfect buffer for a wide range of fragile products across various industries.
Common applications for bubble wrap packaging include:
- Fragile Homewares and Decor: Ideal for protecting ceramics, glassware, luxury mirrors, and intricate lighting fixtures.
- Sensitive Electronics: Provides a quality protective layer for computer components, circuit boards (using anti-static versions), and laboratory equipment.
- Automotive and Industrial Parts: Used by dealers and manufacturers to protect precision car parts, polished metal components, and machined tools from vibration damage.
- Polished or Painted Surfaces: Essential for ensuring that painted furniture, finished timber, or stainless steel goods do not suffer scuffs or scratches during a long time in transit.
If your goods are traveling long distances across Australia, the consistent cushioning provided by bubble rolls is often the most reliable way to prevent damage.
When to Use Void Fill Packaging
Choose a void fill solution when your product is relatively sturdy, but you need to eliminate empty spaces within the shipping boxes to prevent movement. While the item itself might be durable, excessive movement within the carton can result in the product punching through the cardboard walls or damaging other items in the same order.
Void fill products are highly effective for:
- Heavy Hardware and Tools: Prevents metal tools, fasteners, or industrial components from shifting and compromising the box’s structural integrity.
- Consolidated Retail Orders: Void fill provides a "nest" for multiple items in one box, keeping them separated so they do not collide.
- E-commerce Fulfilment: A cost-effective and fast way to fill the voids in standard-sized boxes used for non-fragile goods like books, packaged retail products, or apparel.
- Irregularly Shaped Freight: Filling voids can prove more efficient than trying to wrap an awkwardly shaped item.
Void fill products provide a "nest" for multiple items in one box. By keeping the items separated with paper void fill (compatible with wall-mounted dispensers) or loose fill, you prevent them from hitting each other.
Browse our range of void and loose fill options here.
Combining Both for Superior Protection
In many cases, the perfect packaging strategy involves using both. We often recommend this "layered" approach for high-value goods:
- First, wrap the item in bubble film and secure it with tape.
- Place the wrapped item in the center of the box.
- Fill the remaining void with loose packaging materials to block it in place.
This ensures that even if the box is crushed, the product has enough cushioning to survive, while the void fill ensures the item doesn't move toward the edges of the box where damage is most likely to occur.
Environmentally Friendly and Specialised Options
As an Australian family-owned business with years of experience, we provide a range of protective packaging solutions catering to specific industrial requirements and environmental considerations. By selecting the right specialised material, you can ensure your packaging needs are met while maintaining high standards of protection and efficiency.
Anti-Static Bubble FilmDesigned specifically for the electronics industry, this specialised wrapping protects sensitive components from static discharge during transit. It is a critical product for keeping high-value electronic goods safe from invisible electrostatic damage. You can find our Anti-Static Bubble Film here. |
 |
 |
Bio-Degradable Void FillFor companies looking for a more sustainable alternative, our starch-based void fill is a 100 per cent compostable solution. This material provides the same quality cushioning and space-filling protection as traditional peanuts but breaks down naturally, making it a perfect choice for customers looking for high-performance plastic alternatives. View our Bio-Fill options here. |
Inflatable Air Pillow SystemsOur air pillow packaging represents a high-efficiency hybrid selection for modern despatch areas. These pillows arrive as compact, flat rolls, significantly reducing the storage space required in your location compared to pre-inflated bubble rolls. When inflated on demand by specialised void fill machines, they provide a durable, air-filled buffer that is highly effective for suspending items in the centre of boxes to prevent impact damage. Explore our Inflatable Air Systems here. |
 |
 |
Honeycomb Kraft Paper SleevesFor businesses shipping cylindrical items such as bottles or glassware, our honeycomb kraft paper sleeves provide a ready-to-use protective solution. Sold as discrete units, these sleeves expand into a honeycomb structure that creates a cushioning layer, conforming closely to the shape of the product. This helps protect against surface damage and impact during transit. They offer a practical and environmentally friendly alternative to bubble wrap, making them ideal for e-commerce operations looking to reduce plastic while still ensuring fragile items arrive in perfect condition. Learn more about our Honeycomb Kraft Paper Sleeves solution. |
Honeycomb Kraft Paper WrapHoneycomb kraft paper wrap (also known as expanding paper) is a highly versatile paper void fill and wrap hybrid. Supplied in a convenient dispenser, the kraft paper stretches into a honeycomb structure to provide superior protection for irregular-shaped items and fragile products. Because it interlocks with itself, it often eliminates the need for tape, improving packing efficiency. It is an ideal plastic alternative that provides two layers of defense: surface protection and impact absorption. Learn more about our Honeycomb Kraft Wrapping Paper solution. |
 |
Why Choose Azapak for Your Protective Packaging Needs?
Azapak has been a trusted location for quality supplies for decades. We make it easy to access high-quality warehouse packaging consumables with transparent pricing and nation-wide delivery throughout Queensland, NSW, Victoria and beyond. With Azapak, you can be confident that you won’t pay more than you need to for an industry-leading solution.
Register today to create an account. Need help before proceeding with a purchase? We’re happy to assist you wherever we can. Contact our office on 1300 255 725 or email sales@azapak.com.au today.
