Void fill is one of those packaging details that often gets overlooked until it becomes a problem. When you’re packing something valuable or fragile, how you fill the space around that item inside the box can mean the difference between a safe delivery and a product arriving in pieces. Shipping puts a lot of stress on packages. What doesn’t move inside a box usually survives the journey. But when there’s too much empty space or not enough cushioning, even the toughest box won’t be able to do the job alone.
Fall is a busy time for shipping around Rochester, NY. As companies gear up for holiday and end-of-year deliveries, packaging demands tend to shift. It’s a good time to reassess how your packaging performs under load. This piece walks through how to spot when your void fill levels aren’t cutting it anymore, the different materials you can use, and how to make better choices that keep your products intact.
Signs You Need More Void Fill in Your Packaging
There are some telltale signs that your packaging isn’t providing enough protection. You may not notice them right away, but over time they show up in the form of damage, returns, and customer complaints. Most of the time, it’s not because the outer box failed. It’s what was going on inside that caused the issue.
Here are a few red flags to watch for:
– Products shifting inside the box during transit or unpacking
– Items arriving at their destination with dents, scratches, or broken parts
– Tamper seals or secured closures coming loose more often than expected
– An increase in return requests directly tied to damaged shipments
– Packaging that looks beaten or collapsed even if the product is okay
Some businesses see these issues pop up as they scale up shipments or start sending heavier products. Something that worked for a lightweight item may not hold up once you’re dealing with more weight or bulkier contents. Large items with uneven shapes or sharp corners are particularly at risk if they’re moving around in a loosely packed box.
You might also notice that your packing process is inconsistent. Some boxes are packed tightly while others have you stuffing in last-minute filler just to take up space. That inconsistency points to a bigger problem. Your void fill materials or method might not match your product’s needs anymore.
If any of that sounds familiar, it’s probably time to rethink how much cushion your box provides.
Understanding Types of Void Fill Materials
Once you’ve decided that it’s time to level up your packaging, the next step is choosing the right void fill material. Different products call for different levels and types of protection, and not every filler works for every situation.
Here’s a breakdown of common void fill materials and their ideal uses:
1. Paper: This is one of the most common types of void fill. It’s great for general cushioning and can be crumpled to fit around products easily. It performs well for lightweight to medium-weight items but may not offer enough padding for fragile goods.
2. Air Pillows: These are plastic cushions filled with air. They offer lightweight yet reliable protection. They’re best for items that are not too delicate but still need to stay in place. They’re also neat and take up less storage space.
3. Foam Peanuts: These small, irregularly shaped fillers are good for wrapping around odd-shaped items. They settle around products and fill gaps, but they can be messy and are often disliked during unpacking.
4. Foam Sheets or Rolls: These provide strong barrier protection and are especially useful for heavy or sharp products. They cost more but offer reliable protection when needed.
5. Molded Inserts: These are custom packaging components designed to fit your product exactly. They require more upfront work but provide a precise fit and solid protection, especially for high-value items or equipment.
Each has its benefits and drawbacks. Your choice depends on what you’re shipping and how far it’s traveling. For consistent products, standardizing your void fill can make packing easier. If what you ship varies, keeping multiple materials on hand and mixing based on the shipment helps cut down on waste and damage.
Pick what works best for protection, not only what’s cheap or easy. The outer box can only do so much. The real protection often comes from within.
Benefits of Increasing Void Fill Protection
Adding more effective void fill isn’t just about preventing those one-off damage reports. It can actually improve a lot of other parts of your operation. When the package is well padded inside, it travels better, your team feels confident packing it, and your customers are happier when it arrives intact.
Fewer damaged shipments mean fewer return claims, fewer complaints, and less time spent replacing items. That reduces stress on your warehouse and customer service teams. You also save money by avoiding reshipping the same item twice.
Well-filled boxes also mean you’re giving off a stronger impression of care and quality. Clean presentation matters. It tells the person opening the box that the contents are worth protecting. That matters more when someone is giving the product as a gift or counting on it arriving in good shape right away.
People remember when things arrive in perfect condition. Your packaging becomes part of your reputation. When your boxes hold their shape and the product inside doesn’t move around at all, you build repeat trust with your buyers.
This all becomes even more important during the busier seasons in places like Rochester. End-of-year spikes in volume mean more risk. Stronger void fill choices heading into the holiday rush reduce that risk and protect your bottom line.
Better void fill doesn’t just protect your product. It also protects your time, dollars, and brand image along the way.
Tips for Choosing the Right Void Fill Level for Your Needs
Getting void fill right means balancing protection with practicality. If you’re trying to improve your packaging, start with these steps.
1. Take Stock of Your Products
Look at the kinds of items you’re packing. Are they fragile? Heavy? Does the shape make packing tricky? Each detail helps when picking a filler.
2. Review Your Current Packaging Failures
Go over items that came back scratched, broken, or with packaging issues. Whether it’s one item or a group, repeat trends often hint at what needs improvement.
3. Test New Materials Before Committing
Run a few small-scale tests with different void fill types. Send out samples through your normal shipping routes and check how they hold up.
4. Match Filler to Box Size
Oversized boxes with loose void fill often lead to more shifting and damage. Choose fillers and boxes that fit well together to keep the product from moving.
5. Get Outside Input When Needed
If you’ve adjusted your packaging and things still go wrong, talking to packaging experts can help. They’ve seen a lot of different problems and know how to troubleshoot quickly.
Once you sort out the right mix, everything else moves smoother. Packing becomes faster, your team avoids guesswork, and your risk of damage drops.
Take the time to test, gather feedback, and involve experts when needed. Small steps now can save a lot of stress later on.
Be Confident Your Products Are Secure
Good packaging isn’t only about getting something from one place to another. It’s about making sure it gets there in the condition your customer expects. When you use the right void fill with the right box, you give each shipment its best shot at arriving safely.
Fall can be one of the most demanding times for shipping around Rochester. With shipping activity ramping up, now’s a practical time to step back and take a closer look at your packaging methods. Whether your products are heavy, fragile, or just oddly shaped, they all deserve care that goes beyond the outer box.
Paperboard box packaging paired with the ideal void fill can give your shipments the dependable protection they need. When your team can pack confidently and your customers receive boxes that look like they were never jostled, everyone wins.
If it’s been a while since you reviewed or adjusted your void fill strategy, don’t wait any longer. Now’s a perfect time to tune it up and make sure you’re delivering quality from box to doorstep.
Choosing the right packaging solution plays a big role in keeping your products safe from the warehouse to your customer’s doorstep. At Orcon Industries, we specialize in helping businesses find solutions that work. If you’re looking to boost protection and streamline shipping efficiency, take a closer look at our paperboard box packaging designed to meet your unique needs.
