The two jobs protective packaging does;
1. Wrapping — protection against the product itself
Wrapping sits directly against the product's surface, protecting it from scuffs, scratches, and impact. This is the job bubble wrap or foam traditionally does, though there are now several alternatives.
- Air cushion film (bubble or tube/ quilt format) — inflated on demand
- Honeycomb paper wrap — expands into a 3D mesh that conforms to the product's shape
- Corrugated cardboard wrap — surface and scratch protection for less fragile items
See our full bubble wrap alternatives guide for a detailed comparison of these.
2. Void fill — protection against movement in the box
Void fill goes around the product(s), filling the empty space in the box so nothing shifts, no products collide with eachother or the side of the box, or arrive rattling loose. This is typically needed where different combinations of various products are packed in a box and variable voids need filling, but can also apply to one product in a box to offer more protection.
- Air cushion pillows — on-demand, low storage space, quickly dispended
- Paper void fill — plastic-free, recyclable with the box
- Loose fill / packing peanuts — practical for irregular shapes, higher storage cost
- Foam inserts — premium protection tailored perfectly to the size of box and repeat-shaped products, often high-value items
See our full void fill packaging guide for how to choose between these based on your volume, storage space, and product fragility.
Do you need both?
Usually, yes, but the balance depends on your product(s):
Fragile, easily scratched (glass, ceramics) Wrapping: yes — surface protection is essential. Void fill: yes — prevents impact from movement.
Sturdy, boxed goods (books, homewares) Wrapping: often minimal or none. Void fill: yes — mainly to stop shifting.
Irregular shape, non-fragile (clothing, soft goods) Wrapping: rarely needed. Void fill: minimal — light fill to stop rattling.
High-value electronics Wrapping: yes — scratch and static protection. Void fill: yes — often foam for a precise fit designed with the box in mind. Then non-foam void fill if multiples boxes in an outer box/ shipper.
Heavy/ large/ awkwardly shaped (Industrial) Wrapping: less needed as surfaces often robust. Void fill: yes to support, stabalise and offer heavy duty cushioning. High grammage padded paper is a good example.
A common mistake
Businesses often reach for one type of protective packaging and use it for both jobs — wrapping a fragile item in bubble wrap, then stuffing the remaining space with more bubble wrap as void fill too. It works, but it's usually not the most cost- or space-efficient approach, and certianly not cost or eco efficient. Using the right material for each job — a wrap suited to the product's surface, and a separate void fill suited to the box's remaining space — typically protects better while using less material overall.
Related questions
Is protective packaging the same as void fill? No — void fill is one type of protective packaging, specifically for filling empty space. Protective packaging also includes wrapping, which protects the product's surface directly. And protective packaging can apply outisde of boxes such as securing and protecting on a pallet.
What's the most sustainable protective packaging option overall? It depends on the product and priority. Recycled-content air cushion systems minimise material use (99% air, 1% plastic) across both wrapping and void fill; paper-based options remove plastic entirely but weigh more per parcel. Neither is universally best — see the linked guides above for the specific trade-offs. And as you'll read in other guides, the most sustainable is often the one which prioritises protection from damages. Ideally done with no more material than needed.
Do I need different protective packaging for different products? Often, yes. A business shipping a mix of fragile and sturdy items typically benefits from having more than one protective packaging system available, rather than using a single material for everything. Some systems, like air cushion machines, can prodcuce various shapes and sizes of materials to suit various packing jobs.
Forever Green Packaging supplies air cushion systems and film, paper void fill systems and papers, and gummed paper tape systems and tapes — with no minimum order and next-day delivery. Not sure where to start with our stock items? Our free "try before you buy" service repacks a typical order of yours and we send back with a full comparison report. And if you have a more technical brief such as bespoke foam needed, we'd be pleased to visit and offer you the best options.