Also known as: Dunnage, Fill Material
Void fill is loose material used to occupy empty space in a carton so contents cannot move. It stops movement but provides little impact protection — a distinction that matters, because a pack relying on void fill alone usually fails a drop test.
Void fill and cushioning are different jobs that are constantly confused. Void fill immobilises: it stops a product sliding into a carton wall during handling. Cushioning decelerates: it absorbs the energy of an impact so the product does not feel it.
Loose fill — air pillows, paper, foam peanuts — does the first job well and the second badly. Under a drop, loose material migrates away from the impact zone and the product ends up hitting the carton wall through a gap that has just opened up.
The correct use is as a supplement. A product held in a die-cut foam cavity is properly cushioned; void fill around the outside then stops the whole assembly rattling. Using void fill instead of a cavity is where packs fail.
The cheapest genuine improvement most shippers can make is right-sizing the carton so there is very little void to fill in the first place. That cuts material cost, dimensional-weight charges and damage rate at the same time.
Void Fill at a glance
| Purpose | Immobilisation, not impact absorption |
|---|---|
| Common types | Air pillows, kraft paper, foam peanuts, foam offcuts |
| Failure mode | Migrates away from the impact zone under drop |
| Correct use | Supplement to a cushion, never a replacement |
| Better alternative | Right-size the carton to remove the void |
Common questions
Is void fill enough to protect a fragile product?
No. Void fill stops movement but does not absorb impact energy, and it migrates away from the impact point during a drop. Fragile products need a cushion or a die-cut cavity, with void fill only as a supplement.
What is the difference between void fill and cushioning?
Void fill occupies empty space so contents cannot shift. Cushioning absorbs impact energy so the product decelerates gradually. A pack usually needs both, and cushioning is the one that determines whether it survives a drop.
Need Custom Corrugated Boxes for your product?
We manufacture custom corrugated boxes at our Rajkot unit and dispatch across India. Send the product, size or weight and monthly quantity and we specify and quote within one working day.
Or read the full specification: Custom Corrugated Boxes