What Is a Void Filler?
Void fillers are materials used to occupy empty spaces within packaging, whether inside individual boxes, on pallets, or within larger containers. Their purpose is to fill those gaps to prevent items from moving and colliding with each other during transit, thereby reducing impact damage. Common void fillers include corrugated inserts, air pillows, and crinkle paper, as well as more engineered solutions like void fill packaging components and dunnage bags.
Please read our detailed guide on Void Fillers: The Ultimate Guide to Protective Packaging
Enhancing Stability with Void Fill Packaging
Void filler packaging solutions, such as corrugated drop fillers serve as rigid braces inside shipping containers. These fillers stabilize loads, especially single pallet loads placed in the middle of a truck. Dunnage Systems Inc. offers customized Dual Drop Void Fillers. These dual drop void fillers are made from sturdy corrugated materials and aim to eliminate side-to-side shifting. These types of solutions preserve proper axle weight and load integrity.
Cushioning Impacts and Absorbing Vibration
While providing support is an important function of void fillers, providing cushioning solutions is equally important. Some void filling methods provide cushioning by providing vibrations, tremor absorption and by providing a more uniform and broader force distribution. Although basic protection is offered by corrugated fillers, void filling solutions such as inflatable dunning bags offer advanced protection. When placed between loads such as pallets and boxes, these airbags fill the gaps, absorbing shocks and preventing loads from shifting.
Balancing Cost, Reusability, and Efficiency
A smart void filler strategy balances protection, cost, and sustainability. Corrugated drop fillers typically offer a lower upfront cost and easy recyclability, making them a cost-effective choice for many operations. On the other hand, dunnage bags, especially polywoven or moisture-resistant types, may incur a higher initial cost but offer reusability and enhanced protection—ideal for irregular or fragile cargo.
Optimizing Space and Environmental Impact
Choosing the right void filling solutions can also improve freight efficiency and reduce environmental waste. Traditional void fill materials (like foam peanuts or excess plastic wrap) often consume unnecessary volume and contribute to higher freight costs and waste. In contrast, precisely designed void filler packaging materials—specifically tailored for the space available—reduce shipping volume, walk toward sustainability, and minimize return rates due to damage.
Safety Benefits Across Modalities
Safety doesn’t stop at packaging. Well-secured cargo means safer handling for warehouse personnel, fewer incidents during loading/unloading, and lower risk of damage from sudden stops or rough handling. Dunnage bags serve this purpose effectively: they stabilize cargo, offer shock resilience, and deliver safety across modes—whether trucking, rail, or ocean containers.
Selecting the Right Void Filling Solutions for Your Needs
Here are key considerations when choosing between different void filler and void filling solutions:
- Cargo Type: Fragile items might benefit more from cushioned airbags; standard palletized goods may do well with corrugated void fillers.
- Budget vs. Long-term Value: Corrugated void filler may cost less initially; dunnage bags may deliver better ROI through reusability and fewer replacements.
- Environmental Goals: Corrugated solutions are easily recyclable; reusable dunnage bags reduce long-term waste footprint.
- Storage and Handling: Flat-folded corrugated fillers save storage space; inflatable dunnage bags need only deflation space.
Read more: A Guide to Choosing the Right Void Filler
Summary of Benefits
| Benefit | How Void Filler Achieves It |
| Prevents shifting | Fills gaps with structured material or inflated airbags |
| Provides cushioning | Absorbs impacts and dampens vibration |
| Enhances safety | Stabilizes cargo - safer for handlers and transport |
| Reduces product damage | Minimizes impacts, friction, and pressure |
| Cost-efficiency | Optimized designs reduce waste and return costs |
| Environmental gains | Recyclable or reusable options lower footprint |
Final Thoughts
The implementation of professional void filler systems represents a strategic investment that delivers measurable benefits across safety, cost reduction, and customer satisfaction metrics. As shipping volumes continue growing and customer expectations increase, the importance of effective void filler packaging will only intensify. Companies seeking comprehensive cargo protection should partner with experienced providers who understand the complexities of modern transportation challenges.
Dunnage Systems Inc. offers industry-leading void filling solutions designed to meet diverse shipping requirements while maintaining cost-effectiveness. Their extensive range of dunnage bags and specialized void filler products provides customizable protection strategies that address specific cargo characteristics and transportation needs.