When to Use Void Fill (Loose Fill): Timing, Triggers, and Packing Scenarios

Void fill (loose fill) is not a one-size-fits-all solution; knowing when to use it helps minimize damage, control cost, and deliver a better customer experience. This guide identifies the common triggers and scenarios that indicate loose fill is the right choice.

When you have empty space in the package

The simplest trigger for loose fill is obvious: empty space. If items don’t snugly fit the box or container, they can shift during handling. Use loose fill to immobilize products, ensuring they remain in one position and reducing impact from drops or corner knocks.

When products are fragile or irregularly shaped

Loose fill is particularly helpful for fragile items (glassware, ceramics) and irregular shapes that don’t conform to standard inserts. It conforms around contours, providing cushioning and preventing part-to-part contact.

When multiple items are shipped together

Orders with multiple SKUs in one box benefit from loose fill to separate items and prevent rubbing or collision during transportation. Shredded paper or foam peanuts provide inexpensive separation.

When packing speed and flexibility matter

If your operation handles a large variety of SKUs and needs fast packing without custom tooling, loose fill is a practical choice. It speeds up the packing process and adapts to different item mixes without preconfigured inserts.

When you want to reduce returns and damage claims

High damage rates justify spending on better internal protection. If returns and carrier claims are costly, introducing the right loose fill as part of a protective packaging strategy can reduce transit damage and lower total logistics costs.

When box selection is constrained

Sometimes businesses use standard box sizes to simplify operations. When the box doesn’t match item geometry, loose fill compensates for the mismatch by filling voids and providing cushioning.

When packaging presentation matters

For consumer goods where unboxing is part of the experience, paper-based loose fill or crinkle fill can provide a premium look while still protecting products.

When to avoid or reconsider loose fill

• High-value or very fragile goods: For some electronics, medical devices, or precision instruments, engineered foam inserts, molded supports, or custom trays may be necessary to meet protection and liability standards.
• When cleanliness is critical: Loose fill may shed dust or fibers, making it unsuitable for sterile or highly sensitive parts.
• In transit through very long or harsh supply chains: Long transit times or multiple handlings might require more durable protection than loose fill alone can provide.

When to switch materials or strategies

1. Seasonal peaks: During peak shipping seasons, choose materials that speed packing and reduce costs (e.g., air pillows for rapid, consistent fill).
2. Customer feedback and returns: If you see return patterns linked to damage, reevaluate your fill type: upgrade from paper to molded inserts or combine loose fill with edge protection.
3. Environmental policy changes: If sustainability becomes a priority, switch from EPS peanuts to starch-based or recycled paper options.
4. Cost analysis: Monitor cost-per-shipment and damage cost; change fill type when the ROI favors an alternative.

When implementing in workflows

• Introduce clear packing rules: specify when to use loose fill by product class, weight, and fragility.
• Use packing software or WMS rules to recommend box sizes and fill types for each order.
• Train seasonal temporary staff specifically on fill quantity and placement to avoid under- or over-filling.

Quick decision checklist — use loose fill if:

• The box has unfilled air gaps around items.
• Items are irregularly shaped and need flexible cushioning.
• Speed and low cost are priorities and damage risk is moderate.
• Presentation is important and paper-based options meet both protection and branding goals.

Conclusion



Knowing when to use loose fill helps you balance protection, cost, and customer experience. Use it for gap filling, mixed-item orders, and high-mix packing lines. Reconsider or supplement it for very fragile, valuable, or sensitive items. Regularly review damage rates and customer feedback to determine if and when to change your void-fill strategy.