Void Fill Packaging India: What to Use Inside Your Box to Stop Damage

Void fill is the packaging material that fills empty space inside a corrugated box after the product is placed. It prevents the product from moving during transit, which prevents impact damage when the product hits the box wall.

The cardinal rule of packaging: no product should be able to move inside a sealed box. If you can hear the product shifting when you shake the box, it will be damaged in transit.

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Why Void Fill Matters

When a filled and sealed box is dropped from 50cm — which happens regularly in courier hubs and warehouse loading operations — the product inside continues travelling downward at the same velocity as the box until it hits the box wall. The impact is proportional to the distance the product travels and the mass of the product.

A 500g object travelling 50mm before impacting a corrugated wall creates an impact force of approximately 50 to 100N — enough to chip ceramics, crack glass, and bend fine metal components.

Correct void fill eliminates this travel distance. The product is held in position from all sides and cannot accelerate toward any wall.

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Types of Void Fill and When to Use Each

Crumpled Kraft Paper

The cheapest and most widely used void fill in Indian e-commerce and small business packaging.

How it works: Sheets of kraft paper (40 to 60 GSM) are torn and crumpled into balls or strips and packed around the product.

Cost: Rs. 15 to Rs. 25 per kg of kraft paper. Very low cost per shipment.

Best for: Consumer goods, clothing, books, non-fragile items, eco-conscious brands. Good for D2C brands targeting consumers who prefer minimal plastic packaging.

Limitations: Provides cushioning for low-energy impacts only. Does not protect against drops above 50cm or rough handling. Compresses over time and in humid conditions. Not suitable for fragile items.

Bubble Wrap

Plastic film with sealed air bubbles. The air bubbles absorb impact energy.

How it works: Wrap the product in bubble wrap before boxing (product protection), or pack bubble wrap around the product after boxing (void fill and cushioning combined).

Cost: Rs. 30 to Rs. 50 per square metre. Higher cost than kraft paper but better protection.

Best for: Fragile consumer goods, ceramics, glassware, small electronics. E-commerce sellers of fragile products.

Limitations: Bubbles can pop under sustained pressure, losing cushioning effectiveness. Not suitable for sharp-edged products (punctures bubbles). Generates plastic waste.

Upackarts Bubble Wrap Rolls: upackarts.in/products/bubble-wrap-rolls/

Foam Sheets and Offcuts

EPE foam cut to size or used as offcut pieces to fill void space.

How it works: Foam pieces are placed around the product, conforming to the shape and filling gaps.

Cost: Rs. 35 to Rs. 55 per square metre for foam sheet. Foam offcuts from cutting operations cost less.

Best for: Industrial parts, precision components, electronics. Any product where bubble wrap is inappropriate (sharp edges, static sensitivity).

Upackarts Foam Sheets and Rolls: upackarts.in/products/foam-sheets-rolls/

Air Pillows

Plastic bags inflated with air, used for void fill in high-volume e-commerce fulfillment.

How it works: Inflated pillows fill the space between the product and box walls. The air cushions provide light to medium protection.

Cost: Requires an air pillow machine (Rs. 8,000 to Rs. 25,000) plus air pillow film rolls.

Best for: High-volume e-commerce operations (above 200 shipments per day) where kraft paper or foam is too slow to apply manually.

Limitations: High initial machine investment. Provides less protection than foam for heavy or sharp products. Not widely available through standard suppliers.

Foam Peanuts (Loose Fill)

Small expanded polystyrene pieces that fill all void space around the product.

How it works: Pour peanuts into the box around the product until all void space is filled.

Cost: Moderate. Generates significant plastic waste. Messy to work with.

Not recommended for most Indian businesses: difficult to manage in warehouse environments, generates environmental concerns, increasingly refused by customers, and foam peanuts from non-food-grade EPS can contaminate food products.

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How to Calculate Void Fill Quantity

Step 1: Pack your product in the box as normal.

Step 2: Measure the remaining void volume: internal box volume minus product volume.

Internal box volume: L x W x H (internal dimensions)

Product volume: approximate from product dimensions or water displacement

Step 3: Calculate void fill needed:

Kraft paper: 1.5 sheets (A3 size) per 1,000ml of void space

Bubble wrap: 0.5 square metres per 1,000ml of void space (as wrapped filler)

Foam offcuts: 0.8 times the void volume in foam volume

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The Right Void Fill for Each Situation

| Situation | Recommended void fill |

|-----------|----------------------|

| Light consumer goods under 500g | Crumpled kraft paper |

| Fragile ceramics and glassware | Bubble wrap + kraft paper base |

| Electronics | Foam offcuts or anti-static foam |

| Industrial parts under 5 kg | Foam offcuts |

| High-volume e-commerce | Air pillows or kraft paper |

| Premium D2C unboxing experience | Tissue paper + kraft paper |

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Products from Upackarts

Bubble Wrap Rolls: upackarts.in/products/bubble-wrap-rolls/

Foam Sheets and Rolls: upackarts.in/products/foam-sheets-rolls/

3-Ply Corrugated Boxes: upackarts.in/products/3-ply-corrugated-boxes/

5-Ply Heavy Duty Corrugated Boxes: upackarts.in/products/5-ply-heavy-duty-corrugated-boxes/

GST invoice. Delivery across India. WhatsApp +91-88560-64045.

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Frequently Asked Questions

What is the cheapest void fill option for Indian e-commerce?

Crumpled kraft paper is the cheapest void fill at Rs. 15 to Rs. 25 per kg and provides adequate protection for non-fragile products under 500g. For fragile items, bubble wrap provides better protection at slightly higher cost.

Can I reuse void fill materials?

Kraft paper can be reused if not torn or wet. Bubble wrap can be reused if bubbles are intact. Foam offcuts can be reused multiple times. Air pillows deflate on opening and are single-use.

How do I know if I am using enough void fill?

Seal the box and shake it firmly. If you can hear or feel the product moving inside, you need more void fill. The product should be completely immobile inside the sealed box.