Simplicity meets sustainability: Filling the void in eCommerce packaging

August 19, 2025
By Intertape Polymer Group (IPG), for the Blue Print

With eight million pieces of plastic entering the ocean daily, consumers are increasingly concerned about their environmental impact. As plastic air pillows have become a common void fill solution, the need for sustainable alternatives is more urgent than ever. So, what options exist, and how can businesses improve their green practices?

Below, we explore why void fills are necessary, emphasize the importance of sustainability, and highlight a few eco-friendly solutions that can help businesses maintain consumer trust.

Why the void needs filling

Securing packages is essential to protect goods during transit. One of the biggest risks to product safety is the presence of voids—open spaces within packages. Void fill materials cushion these areas, reducing the likelihood of damage and ensuring a better customer experience.
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The importance of sustainability in void fill

Without adopting greener practices, the shipping industry contributes significantly to plastic waste. Traditional void fill materials like plastic peanuts and polystyrene, while effective, are single-use and often end up in landfills or oceans.
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Packaging waste

Recent trends have shifted toward air pockets made from thin plastic sheets. Though these are more efficient, they still pose environmental challenges. Since these materials typically have no reuse value after delivery, they contribute to the growing waste problem.
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Sustainable alternatives

Fortunately, there are several alternatives to traditional void fill materials that are compostable or made from biodegradable sources.
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Paper void fill

Thick, crumpled paper offers a simple and effective way to cushion packages. When made from recycled or sustainably sourced paper, this option reduces deforestation and environmental impact. Paper also biodegrades much faster than plastic—typically within a year or two—without leaving harmful residues.

Its flexibility allows it to fill both small gaps and larger voids, making it a versatile solution for various packaging needs.

Honeycomb paper fill
This type of paper fill features a honeycomb structure that expands to provide cushioning. It’s designed to replace traditional materials like bubble wrap and offers a “soft rigidity” that protects items from light impacts.

The honeycomb design allows the paper to interlock without tape, reducing the need for additional materials. It can also be recycled through standard paper recycling streams, supporting circular economy practices.
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Sustainable packaging delivery solutions

Efficiently inserting void fill can be challenging, especially in high-volume operations. Modern solutions now allow rolls of paper to expand significantly, filling large spaces without requiring bulky pre-made materials.

Dispensing systems are available to help automate and speed up the packing process, making sustainable packaging more practical and scalable for businesses.

High-speed paper dispensing solutions
For operations requiring fast and efficient void fill, high-speed paper dispensing systems can be a game-changer. These systems are capable of dispensing paper at speeds up to 415 feet per minute, making them ideal for larger packages or high-volume packing environments. With the ability to handle paper widths up to 30 inches, they provide substantial material quickly, offering a practical and sustainable alternative to slower plastic-based options.

Automated void fill systems
Automated void fill systems powered by smart technology can significantly reduce the need for manual packing. These systems help optimize material usage by eliminating guesswork, which not only improves packing efficiency but also minimizes waste. By streamlining the process and reducing excess material, businesses can lower their environmental impact and reduce the volume of packaging waste sent to landfills.
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Putting sustainability into practice

Understanding the importance of sustainable packaging is one thing—implementing it is another. Businesses need reliable partners and equipment to make the transition smooth and effective. By choosing eco-friendly materials and efficient delivery systems, companies can protect their products and the planet at the same time.
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​Content originally from Intertape Polymer Group (IPG). Reused here with permission.

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