#void filling solutions

In today’s fast-paced shipping environment, protecting cargo from damage during transit is more critical than ever. One key strategy efficiently minimizing damage and enhancing safety is the use of void filler. Whether you're shipping fragile electronics or heavy pallet units, void filler plays a vital role in securing products, preventing shifting, and absorbing shocks. Let’s unpack how effective void filler strategies can not only protect your goods but also optimize your packing operations.

What Is a Void Filler?

Void fillers are materials used to occupy empty spaces within packaging, whether inside individual boxes, on pallets, or within larger containers. Their purpose is to fill those gaps to prevent items from moving and colliding with each other during transit, thereby reducing impact damage. Common void fillers include corrugated inserts, air pillows, and crinkle paper, as well as more engineered solutions like void fill packaging components and dunnage bags.

Please read our detailed guide on Void Fillers: The Ultimate Guide to Protective Packaging

Enhancing Stability with Void Fill Packaging

Void filler packaging solutions, such as corrugated drop fillers serve as rigid braces inside shipping containers. These fillers stabilize loads, especially single pallet loads placed in the middle of a truck. Dunnage Systems Inc. offers customized Dual Drop Void Fillers. These dual drop void fillers are made from sturdy corrugated materials and aim to eliminate side-to-side shifting. These types of solutions preserve proper axle weight and load integrity.

Cushioning Impacts and Absorbing Vibration

While providing support is an important function of void fillers, providing cushioning solutions is equally important. Some void filling methods provide cushioning by providing vibrations, tremor absorption and by providing a more uniform and broader force distribution. Although basic protection is offered by corrugated fillers, void filling solutions such as inflatable dunning bags offer advanced protection. When placed between loads such as pallets and boxes, these airbags fill the gaps, absorbing shocks and preventing loads from shifting.

Balancing Cost, Reusability, and Efficiency

A smart void filler strategy balances protection, cost, and sustainability. Corrugated drop fillers typically offer a lower upfront cost and easy recyclability, making them a cost-effective choice for many operations. On the other hand, dunnage bags, especially polywoven or moisture-resistant types, may incur a higher initial cost but offer reusability and enhanced protection—ideal for irregular or fragile cargo.

Optimizing Space and Environmental Impact

Choosing the right void filling solutions can also improve freight efficiency and reduce environmental waste. Traditional void fill materials (like foam peanuts or excess plastic wrap) often consume unnecessary volume and contribute to higher freight costs and waste. In contrast, precisely designed void filler packaging materials—specifically tailored for the space available—reduce shipping volume, walk toward sustainability, and minimize return rates due to damage.

Safety Benefits Across Modalities

Safety doesn’t stop at packaging. Well-secured cargo means safer handling for warehouse personnel, fewer incidents during loading/unloading, and lower risk of damage from sudden stops or rough handling. Dunnage bags serve this purpose effectively: they stabilize cargo, offer shock resilience, and deliver safety across modes—whether trucking, rail, or ocean containers.

Selecting the Right Void Filling Solutions for Your Needs

Here are key considerations when choosing between different void filler and void filling solutions:

Cargo Type: Fragile items might benefit more from cushioned airbags; standard palletized goods may do well with corrugated void fillers.

Budget vs. Long-term Value: Corrugated void filler may cost less initially; dunnage bags may deliver better ROI through reusability and fewer replacements.

Environmental Goals: Corrugated solutions are easily recyclable; reusable dunnage bags reduce long-term waste footprint.

Storage and Handling: Flat-folded corrugated fillers save storage space; inflatable dunnage bags need only deflation space.

Read more: A Guide to Choosing the Right Void Filler

Summary of Benefits

Benefit

How Void Filler Achieves It

Prevents shifting

Fills gaps with structured material or inflated airbags

Provides cushioning

Absorbs impacts and dampens vibration

Enhances safety

Stabilizes cargo - safer for handlers and transport

Reduces product damage

Minimizes impacts, friction, and pressure

Cost-efficiency

Optimized designs reduce waste and return costs

Environmental gains

Recyclable or reusable options lower footprint

Final Thoughts