Void Fill vs. Custom Foam Packaging: Pros and Cons

Every company wants to get their products from point A to point B without damage and by using the most cost-effective options possible. Void-fill like packing peanuts and crumpled paper is often the de facto packaging choice purely based on the low initial cost - but is it truly the most cost-effective option available?

Custom foam packaging is a more bespoke solution with a typical higher initial cost - but a proven ability to more effectively protect heavy, expensive, and/or fragile products.

Let’s explore the difference between these two packaging options. 

What Is Void Fill for Packaging?

Void fill is quite literally filling to fill a void, AKA packaging that is stuffed into a box to reduce the tumbling that occurs during shipping. The most common types of void fill include:

• Paper Fill – Crumpled or fan-folded paper
• Air Pillows – Plastic inflated with air
• Packing Peanuts – Loose-fill polystyrene pellets that provide cushion
• Corrugated Fill – Cardboard shredded into strips

As one of the cheapest packaging options on the market, companies often try these options first. Void fill can work for shipping certain products - primarily, lightweight items that aren’t fragile. Consumer goods like books can use void fill as a reasonable protection measure.

However, it’s not the best choice for extremely heavy items, expensive products, or breakable items. Void fill doesn’t provide structure, which means that items will naturally move around inside of their box. This dramatically increases the likelihood of damage. For products that are breakable and/or heavy, void fill is ineffective at protection. 

Additionally, there is no way to calculate the exact amount of void fill that will protect your product effectively. Ultimately, your only option is to fill your box with as much void fill as possible and hope for the best.

Void Fill Pros

• Extremely low upfront cost
• Serviceable at providing protection for non-fragile items
• Can be recycled by the consumer

Void Fill Cons

• Doesn’t offer high quality of protection 
• Extremely limited shock absorption and impact resistance
• Highly dependent on assembly workers to choose “the right amount” - open to human error

Related Content: Case Study: Ship in Own Container vs. Box in a Box

What Is Custom Foam Packaging?

Custom foam packaging is packaging that is cut, molded, or fabricated to match the product(s) you need to ship. With a variety of foam types to choose from, you can get either soft, flexible foam or rigid, extra durable options that match your items precisely. Whether you’re sending heavy items or something soft and breakable, foam can match the exact weight requirements and ensure the product fits nice and snug in any box. That way, nothing arrives at its destination damaged.

What Custom Foam Packaging Options Are Available?

• Foam-in-Place (FIP) – Foam is squirted in and forms around a product or shape
• Polyethylene Foam (PE) – Dense foam with high impact resistance, ideal for heavy objects
• Polyurethane Foam (PU) – Soft foam with great cushioning that’s perfect for lightweight and fragile products
• Expanded Polystyrene (EPS) – Rigid yet lightweight foam with great thermal insulation

Additionally, we can calculate the exact type, density, and size needed for your product. Foam is a much more data-backed packaging option. Based on the anticipated force your box will be subjected to (aka: traveling by freight, air, and water; potentially being dropped; jostled around in a mail truck), we can calculate the precise foam solution to protect your part. That’s something void fill can’t replicate.

Related Content: What is a Cushioning Curve?

Foam Packaging Pros

• Reliable protection and shock absorption for heavier items and rough handling
• Custom fit and secure hold ensures breakable items stay intact during shipping
• Provides extra cushion and protection for fragile, breakable items
• Better unboxing experience for premium products

Foam Packaging Cons

• More expensive initial investment, often paid off in reduced damage claims
• Not always recyclable by the end consumer
• A completely bespoke and custom solution - may not be the right fit for standard items

Comparing Custom Foam Packaging vs. Void Fill

When deciding which packaging option is best for your products and your company, it’s important to ask yourself a few questions:

• How fast do you need to get products packaged up and through your shop?
• Do you trust your assembly workers to package products properly every time?
• Would you rather spend more to avoid sending a second time?
• Do you want to improve customer satisfaction?

Ultimately, custom foam packaging is going to offer a faster, easier experience when assembling products for shipping. It offers a fail-proof way to package up your goods safely. While void fill has a much lower initial cost, the “cost” of using the wrong protective packaging can be much more expensive. If you need to re-send an item because it arrived damaged, you’re paying 2-3X more for each product. And you’re “paying” in other ways too - in your reputation with customers.

Customers who receive their product perfect the first time around are going to be more pleased with your company, product, and service, too. Void fill may be the cheaper option initially, but it’s not always the cheapest option in the long run.

Related Content: How Protective Packaging Improves Reverse Logistics

Custom foam packaging and void fill both have their uses, but knowing when to use which one is crucial in protecting your products during shipping. If affordability at any cost is your priority, void fill will likely be your best option. If you’re trying to send high value items or need to ensure that your products aren’t damaged during shipping, custom foam packaging is your best option, by far.

Need Help Choosing the Right Packaging Option?

As a leader in the packaging industry, Foam Industries has set the bar with an unwavering commitment to quality, exceptional client service, and constant innovation. Through our extensive inventory of endlessly customizable products, we ensure you find exactly what you’re looking for.

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Foam Industries is a custom protective packaging company specializing in foam – with additional wood and plastic fabrication services. Our custom foam fabrication services are ideal for any type of packaging, display, or support service needed – from design to finished product.