Where to Use Void Fill (Loose Fill): Best Locations, Industries, and Packaging Spots

Void fill (loose fill) is used wherever items need physical support, immobilization, or cushioning inside a package. Understanding the most effective "where" to use loose fill helps warehouses, shippers, and eCommerce sellers prevent damage, control costs, and improve customer experience.

Where inside a package to place void fill

• Under the item: Place a base layer of loose fill to lift products away from the bottom of the box and reduce shock transmission from drops.
• Around the item: Surround all sides to eliminate movement. Ensure even coverage so the product doesn’t tilt or contact the box walls.
• On top of the item: Add a final layer to prevent vertical compression and to lock items in place once the box is closed.
• Between multiple items: Use loose fill to separate products that could rub or collide, particularly for multi-item orders.

Where to use void fill by industry

• eCommerce and direct-to-consumer retail: Widely used to protect varied product assortments shipped in the same box. Paper or crinkle fill is common for consumer-friendliness and unboxing aesthetics.
• Fulfillment centers and 3PLs: Use loose fill across high-mix order profiles. Automated dispensers for air pillows or paper rolls can be located at packing stations for speed.
• Manufacturing and assembly plants: Use loose fill when shipping irregular components or when custom inserts are not cost-effective.
• Distribution centers: Employed for bulk shipments where internal movement could damage product or packaging during palletization.
• Gift and subscription boxes: Often use decorative crinkle paper or shredded paper as both protective and presentation elements.
• Arts, antiques, and fragile goods: Use soft paper fills or natural fibers inside crates or boxes to protect delicate surfaces.

Where to source and store loose fill

• On-site at packing stations: Keep dispensers or bins within arm’s reach of packers for efficiency. Air pillow machines, paper dispensers, or bulk bins for peanuts are common.
• Central storage areas: For high-volume users, store bulk rolls or bags on pallets in a dedicated packaging materials area to streamline replenishment.
• Local packaging suppliers: Many businesses purchase loose fill from local packaging wholesalers who can supply eco-friendly options.
• Online suppliers: Small sellers often buy consumer-sized quantities from eCommerce suppliers that deliver directly to their location.

Where not to use loose fill

• Hazardous liquids or powders: Loose fill is generally inappropriate for packages that could leak or contain materials that must be constrained in sealed internal packaging.
• When strict cleanliness is required: Medical devices or sterile components typically need tamper-proof, sealed packaging rather than loose fill that could introduce particulates.
• Environments where cleanup is costly: If recipients are likely to discard or make a mess (e.g., small children, sensitive retail displays), using loose fill may be impractical.

Where to dispose or recycle loose fill

• Recycling centers and municipal programs: Paper-based fills are widely recyclable. Plastic air pillows and films are recyclable in some regions but usually require collection with plastic bags/films at store drop-off points.
• Composting: Biodegradable starch peanuts and uncoated paper fills can often be composted in industrial or home systems (check local guidelines).
• Reuse: Many businesses encourage customers to retain loose fill for reuse; some package inserts can explain reuse options to reduce waste.

Where to integrate loose fill into packing workflows

1. Place dispensers at each packing station for consistent application and to reduce motion waste for workers.
2. Train packers on minimum and maximum fill levels based on box size and product fragility.
3. Integrate quality checks at staging or QC stations to verify adequate fill and to reduce returns for damage.
4. Use packing algorithms in warehouse management systems to recommend box sizes and suggest appropriate void fill types and quantities for each order.

Conclusion



Knowing where to use void fill — both inside the package and within your operations — is essential for efficient, protective, and sustainable packing. Whether at a single packing station in a small business or across high-speed fulfillment lines in a large warehouse, proper placement, sourcing, and disposal strategies make loose fill a practical tool for many shipping scenarios.