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Air Cushion Packaging Machines & Recycled Film
Affordable, compact machines that produce protective air cushions, bubble wrap and tubes on demand — using film made from 50% recycled content. Save space, time, money, returns and the environment.
What is air cushion packaging?
Air cushion packaging is a modern protective packaging method where a small desktop machine inflates rolls of lightweight plastic film into air-filled cushions, pillows, bubble quilts or tubes. These inflated cushions are then used inside boxes to protect products during shipping — filling empty space (void fill), wrapping fragile items, or cushioning products against impact. If you're currently using bubble wrap, loose fill peanuts, scrunched-up paper or foam chips to protect your products in transit, air cushion packaging does the same job — but faster, cheaper and with less storage space required. A single roll of flat film, about the size of a large kitchen roll, inflates into the equivalent of approximately 6 bags of loose fill. That's a genuine game-changer for businesses with limited warehouse space.
How does it work?
The process is simple. You load a roll of flat film into the machine, plug it in, and press start. The machine feeds the film through heated sealing bars while pumping air into each cushion. The inflated cushions come out on a continuous perforated strip — you just tear off what you need for each parcel. The whole process takes seconds, and most machines require zero training to operate. Plug and play, literally.
Our air cushion machines
Forever Green was born to make the benefits of packaging systems affordable to smaller businesses and cheaper for larger businesses. Historically, only high-volume users could accommodate minimum order quantities and high capital expenditure. Here, you can buy whatever material you need, when you need it, for the system that suits you.
Entry Level
Shadow Boxer Mk2

Simple, reliable and in everyone's corner. Low cost that soon pays for itself with cheaper ongoing material costs, while offering quicker packing and saved space versus bulky materials.

  • Speed: up to 5m/min
  • Produces bubble, pillows & tubes
  • Adjustable sealing temperature & air fill
  • Compact desktop design
  • Warranty & spare parts included

Best for:Startups and small businesses shipping up to 50 parcels/day

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Best Seller
Silver Pack Mk2

Your competitive all-rounder, compatible with efficiency-gaining accessories like winders. Extra machine features lead your packing team the right way.

  • Speed: up to 16m/min
  • Produces bubble, pillows & tubes
  • Pre-set dispense length
  • Adjustable speed, sealing temp & air fill
  • Compatible with bubble winder & trolley

Best for: Growing businesses shipping 50-200+ parcels/day

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High Performance
Navy Seal

Does everything the others do, plus compatible with multiple hoppers and 800mm wide bubble. More technical or demanding packing frontlines can rely on this rare breed.

  • Speed: up to 30m/min
  • Produces bubble up to 1 metre wide, pillows & tubes
  • Pre-set dispense length
  • Adjustable speed, sealing temp & air fill
  • Compatible with multiple hoppers

Best for:High-volume operations and distribution centres

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Not sure which machine is right?That's exactly what we're here for.Talk to Tom— he'll ask about your volumes, products and space, and give you an honest recommendation. If a machine isn't the right fit for you, he'll say so.
Air cushion film range
Pillows
Tubing
Bubble
Each machine works with the widest range of Forever Green high-quality, environmentally responsible films. All our films contain 50% recycled content and are 100% recyclable.
Pillows / cushions
Film Type
200mm x 100mm Cushion
Size
200 x 200mm
Roll Length
500m
Best For
Smaller boxes, tighter void spaces
Pillows / cushions
Film Type
200mm x 200mm Cushion
Size
200 x 200mm
Roll Length
500m
Best For
General void fill — most versatile size
Pillows / cushions
Film Type
400mm x 150mm Cushion/ Pillow
Size
400 x 50mm
Roll Length
350m
Best For
Larger boxes with bigger voids to fill
Pillows / cushions
Film Type
400mm x 50mm Tube
Size
400 x 50mm
Roll Length
350m
Best For
Blocking, bracing, wrapping & edge protection
Pillows / cushions
Film Type
400mm Quilt
Size
400mm wide
Roll Length
350m
Best For
Surface protection, interleaving, wrapping
Pillows / cushions
Film Type
400mm Bubble
Size
400mm wide
Roll Length
350m
Best For
Wrapping fragile items — glass, electronics, ceramics
Pillows / cushions
Film Type
800mm Bubble
Size
800mm wide
Roll Length
250m
Best For
Larger fragile items (Navy Seal compatible)
Pillows / cushions
Film Type
Size
Roll Length
Best For
200mm x 100mm Cushion
200 x 100mm
500m
Smaller boxes, tighter void spaces
200mm x 200mm Cushion
200 x 200mm
500m
General void fill — most versatile size
400mm x 150mm Cushion/ Pillow
400 x 50mm
350m
Larger boxes with bigger voids to fill
400mm x 50mm Tube
400 x 50mm
350m
Blocking, bracing, wrapping & edge protection
400mm Quilt
400mm wide
 350m
Surface protection, interleaving, wrapping
400mm Bubble
400mm wide
350m
Wrapping fragile items — glass, electronics, ceramics
800mm Bubble
800mm wide
250m
Larger fragile items (Navy Seal compatible)
Air is the ultimate cushioning and protection for your products. The recycled and recyclable films are just 1% of the actual packaging material once the machine has filled it with 99% air. It doesn't get much greener than packing with air — aka nothing.
Why air cushions beat traditional materials
  • Space saving: Film is stored flat on compact rolls. No more filling your warehouse with bags of loose fill or stacks of bubble wrap.
  • Cost effective: Material cost per parcel is significantly lower than pre-made bubble wrap, loose fill peanuts or foam packaging.
  • On demand: Produce exactly what you need, when you need it. Zero waste from overproduction.
  • Versatile: One machine can produce cushions for void fill, bubble for wrapping fragile items, and tubes for blocking and bracing.
  • Lightweight: Air cushions add virtually no weight to your parcels, keeping shipping costs down.
  • Cleaner: No mess, no static, no loose fill escaping across your packing bench.
How air cushions compare to other packaging materials
We get it — switching to a new packaging system is a decision. Here's how air cushion packaging stacks up against the most common alternatives on the metrics that actually matter.
Factor
Air Cushions
Storage space needed
★ Minimal — flat rolls
Cost per parcel
★ Lowest
Speed of packing
★ Fastest — on demand
Mess factor
★ Zero mess
Protection quality
★ Excellent
Recyclable?
★ Yes — 100%
Recycled content
★ 50%
Weight added to parcel
★ Virtually none
Factor
Bubble Wrap
Storage space needed
Large — bulky rolls
Cost per parcel
Medium-high
Speed of packing
Manual tearing/cutting
Mess factor
Minimal
Protection quality
Good
Recyclable?
Limited
Recycled content
Usually 0%
Weight added to parcel
Light
Factor
Loose Fill Peanuts
Storage space needed
Very large — bags
Cost per parcel
Medium
Speed of packing
Slow — scooping & settling
Mess factor
High — static, spillage
Protection quality
Adequate (settles over time)
Recyclable?
Varies
Recycled content
Varies
Weight added to parcel
Light-moderate
Factor
Scrunched Paper
Storage space needed
Moderate — rolls or sheets
Cost per parcel
Medium
Speed of packing
Manual scrunching
Mess factor
Moderate — paper dust
Protection quality
Adequate
Recyclable?
Yes
Recycled content
Varies
Weight added to parcel
Moderate
Factor
Air Cushions
Bubble Wrap
Loose Fill Peanuts
Scrunched Paper
Storage space needed
★ Minimal — flat rolls
Large — bulky rolls
Very large — bags
Moderate — rolls or sheets
Cost per parcel
★ Lowest
Medium-high
Medium
Medium
Speed of packing
★ Fastest — on demand
Manual tearing/cutting
Slow — scooping & settling
Manual scrunching
Mess factor
★ Zero mess
Minimal
High — static, spillage
Moderate — paper dust
Protection quality
★ Excellent
Good
Adequate (settles over time)
Adequate
Recyclable?
★ Yes — 100%
Limited
Varies
Yes
Recycled content
★ 50%
Usually 0%
Varies
Varies
Weight added to parcel
★ Virtually none
Light
Light-moderate
Moderate
Environmental credentials
Forever Green air cushion films are made from 50% recycled content, which means 50% less virgin plastic is needed to produce each roll. Once inflated, the cushions are 99% air and just 1% material — it genuinely doesn't get much greener than packing with air. The films are 100% recyclable and exempt from the UK Plastic Packaging Tax (which applies to packaging with less than 30% recycled content). We also run a Return 2 Recycle service: we send you prepaid mailers, you send back used film, and we ensure it's properly recycled. And with every order, we plant a tree through our partnership with Ecologi.
Accessories to boost your packing efficiency
Air Cushion Film Hopper Trolley
Catches inflated cushions as they come off the machine, keeping your packing bench tidy and your cushions within arm's reach. Wheels let you move it around your packing area.
Bubble Winder & Trolley
Automatically winds inflated bubble film into neat rolls for easy storage and dispensing. Essential for operations producing large quantities of bubble wrap.
We also offer free loan machines for qualifying businesses and efficiency-gaining equipment packages. 
Contact Tom to discuss your options →

Frequently asked questions about air cushion packaging

What is an air cushion machine?

An air cushion machine is a compact desktop device that inflates rolls of flat film into protective air-filled cushions, bubble wrap or tubes. You load a roll of film, plug it in, and it produces packaging on demand meaning you only make what you need for each parcel. Our machines are plug-and-play, require no training, and come with a warranty and spare wearable parts.

How much does an air cushion machine cost?

Our machines are among the most affordable air cushion machines available in the UK, and the ongoing film costs are significantly lower than buying pre-made bubble wrap or loose fill. Most businesses recoup the machine cost within weeks.

Is air cushion film recyclable?

Yes. Our films contain 50% recycled content and are 100% recyclable. They're exempt from the UK Plastic Packaging Tax. We also provide a free Return 2 Recycle service we send you prepaid mailers and you send back used film for proper recycling.

How do air cushions compare to bubble wrap?

Air cushions provide equivalent or superior protection while requiring far less storage space. The film is stored flat and inflated on demand, so a compact roll replaces bulky pre-made bubble wrap. They're also faster to use no cutting or tearing and the 50% recycled content makes them more environmentally responsible than virgin bubble wrap.

Can I try before I buy?

Absolutely. Send us one of your typical orders and we'll repack it using the best materials and methods. You'll receive your package back to experience the unboxing, plus a detailed comparison report covering pack cost, material weight, material type and more. It's completely free.

Do you have minimum order quantities?

No. You can order a single roll of film or a single machine. We don't have minimum order quantities because we know that not every business ships by the thousand. Buy what you need, when you need it.

Can I rent or get a free loan machine?

Yes - depending on your requirements, you can buy, rent or free-loan our machines. Contact Tom to discuss which option makes the most sense for your business.

Inspired by sustainability captains of industry

Try before you buy — it's free
Send us one of your typical orders. We'll repack it using the best materials and methods,and send it back so you can experience the unboxing your customers will get plus a detailed comparison report on cost, weight and materials.