Filling material for packages: close cavities and fix products

Filling material prevents an item from moving freely in the shipping carton. Some materials are additionally upholstered, others are mainly used for presentation. These tasks should be considered separately. A light gift set needs a different fixation than a heavy machine or sensitive glass.

Start with a matching carton

An unnecessarily large carton requires more filling material and often allows more movement. Choose the inner dimension from the article and the required protective packaging. The floor, sides and lids must be considered as well as the gaps between several products.

Pack different articles so that they do not damage each other. Heavy objects shall not be placed on sensitive parts. An additional inner packaging can be more useful for individual articles than large quantities of loose filling material.

Select material by task

• Packaging paper: Buckled or molded to upholstery for cavities and a fixation suitable for load.
• Air cushions: Light cavity filling, if the product and the packaging are suitable for this.
• Air cushion film: For wrapping and separating articles, with matching foil quality.
• Formal operations: For a defined position and coordinated load distribution.
• SizzlePak, silk paper or wood wool: Often decorative; check the necessary transport fixation separately.

Consider weight and surface

Very light fillers can be compressed under heavy content. Then new cavities arise during transport. Check whether the material holds the item in its position and whether sensitive surfaces require a smooth separation layer.

For bulk fillers, composition and handling are important. A bio-based raw material does not automatically mean that the finished product belongs in the biotonne. Statements on disposal and moisture sensitivity must match the specific quality. Observe product specifications and local rules.

How to check the finished packaging

1. Put Article on an appropriate document.
2. Fill gaps, instead of scattering material loosely over them.
3. Separate several objects from each other.
4. Close the lid without overcompressing the contents.
5. Move the package carefully and watch out for loose parts.
6. Document a package sample for recurring shipments and check transport results.

A motion test is a simple control and not a complete transport test. In the case of particularly sensitive or valuable articles, a suitable packaging system needs to be tested as far as possible.

Cost and reuse

Compare costs per ready-packed shipment, not only per bag or roll. Packing time, storage space, trimming and damage rate are included. Clean filling material can often be reused. Few easily separable materials and clear indications make it easier for the recipient to store and sort.