How to Choose an Air Cushion Machine

Let us help you choose between Forever Green’s air cushion machines. It comes down less to daily volume and more to which capabilities you need. This may relate to how many packing stations you're coordinating, whether dispensing pre-set amounts of material matters, and whether our rare extra-large film is needed.

Forever Green's range runs from the entry-level but very capable Shadow Boxer Mk2 (£295) through to the extra functionality of Silver Pack Mk2 (£495) to the high-performance Navy Seal (£695). Each machine adds new features to suit the busyness and needs of varying packing operations.

Start with what each machine adds

  • Shadow Boxer Mk2 (£295) — simple, reliable, affordable and built to handle sustained daily volume. Does the basics well such as capable of producing 7 different film sizes, adjustable air inflation and speed.
  • Silver Pack Mk2 (£495) - adds two things that matter once packing gets busier. 1) its compatibility with the bubble winder. This lets you pre-bundle material to the ideal size so you can distribute it to various packing stations or ready to go in storage. 2) Pre-set dispense length, so the machine reliably produces exactly the amount of material needed without anyone manually measuring or counting. When packing at volume, the time saved per pack really adds up.
  • Navy Seal (£695) — does everything the other two do, plus inflates the widest film on offer (800mm), and is robust enough to be built into a wider hopper system as part of a packing line — filling multiple hoppers continuously through the day. Few competitors offer film this wide, so it's the machine for large or unusually shaped items as well as high-throughput lines. The 800mm bubble is close to regular bubble wrap so these users would benefit moving to this system and making it on-demand, hence saving deliveries, storage and ongoing costs.

The 3 tiers of machines are selected and tested to meet all packing operation demands. It’s also good for customers to know they’re not paying for machine functions they don’t need. Likewise, our 3 tiers mean customers can move up and down depending on their changing business. Forever Green will be flexible on machine changes if a machine is already purchased. Loan machines for higher volume customers can be up or downgraded easily.

One machine, many film formats — a real cost saver

This is worth knowing before you choose: the Shadow Boxer Mk2 and Silver Pack Mk2 both run seven different film formats, more than most competing machines offer, covering everything from tight void-fill cushions to wide surface-wrapping bubble. See film section in Overview. The Navy Seal runs all seven of those plus two more (800mm regular and 800mm small bubble), for nine formats in total.

What this means in practice: a business packing a mixed range of products, say small and large, fragile and sturdy, doesn't need a different machine for each job. One machine covers void fill, wrapping, and blocking/ bracing by simply switching the film loaded, which reduces both the number of machines you need and the complexity of managing separate packaging inventory for different product lines or order multiples.

Think about what you're packing

Beyond machine choice, two things affect which film format makes sense within whichever machine you pick;

  • Item size and fragility —     smaller, tighter void spaces suit narrower cushion formats; larger or more fragile items benefit from wider bubble or quilt film.
  • How varied your products are — the wider your product range, the more this multi-format flexibility actually pays off, since you're not stockpiling different traditional materials for different jobs.

The bubble winder — for pre-bundling and distributing or storing

Alongside the Silver Pack Mk2 and Navy Seal, the Bubble Winder & Trolley is worth knowing about as a standalone compatible accessory. It winds inflated film into neat, pre-bundled rolls, of any pre-set size, rather than requiring it to be produced on demand at the point of packing. That's useful in two situations: producing quilt or bubble in batches ahead of a busy period, or feeding multiple packing stations from one central point rather than running a machine at each location. Combined with the pre-set dispense length function, it lets one machine effectively supply several packers without anyone waiting on it in real time.

The hopper trolley — for moving between stations

Another accessory worth knowing about if you're packing across more than one location is the Air Cushion Machine/ Film Hopper Trolley. It adds mobility, letting you move the film and machine between packing locations rather than being fixed to one spot. It pairs naturally with all three machines.

What determines cost

Machine price scales with capability: £295 for the Shadow Boxer Mk2, £495 for the Silver Pack Mk2, £695 for the Navy Seal (higher-quantity custom pricing is available on request). What's more consistent across all three is the ongoing film cost structure: the machine is a one-off for which the operational benefits alone justify. But the day-to-day cost of the film is where the ongoing pack savings add up. Depending on usage, the pack savings versus traditional materials or competitor films offer a payback time for the machine cost. E.g. see our How quickly does a FGP machine pay for itself vs loose fill. The savings will also apply vs like-for-like films as we offer the most competitive online prices. We also offer custom pricing if your supplier offers better than our online prices, and free loan equipment. If you currently use air cushion packaging and want us to save versus your current deal, or just considering it for your operation, we’re happy to talk.

Still not sure which machine fits?

Understandably changing a system, or considering your first one, might feel unsure. Feel free to send us details such as your volumes, products, how you currently pack and your packing space, and we’ll give you an honest recommendation without committing to a machine that's the wrong size for your operation. We’re also happy to visit and see how you pack first hand and talk, which helps us arrive at the ideal solution. There’s also our Try Before You Buy service, where you send us a typical order of how you currently pack, and we re-pack and send back with our recommendation for size and type of material. This tests the protection, you’ll understand the cost, and have the delivery experience of your customers.

Related questions

Can I switch machines later if my volume changes? Machines aren't locked in — as operations grow or change, it's worth revisiting whether a different tier or an added accessory now fits better than it did at the start. We’ll be flexible with new equipment costs if you’ve already invested. If you’re a free loan equipment customer, we’ll just swap the equipment.

Do all three machines use the same film? The Shadow Boxer Mk2 and Silver Pack Mk2 both run the same seven film formats. The Navy Seal runs all seven of those plus two wider 800mm formats, so it's worth deciding film needs and machine choice together rather than separately.

Is a more expensive machine always the better choice? Not necessarily — the right machine is the one that comfortably covers your actual daily volume and what functions you need, rather than the highest-spec option available. Oversizing usually just means paying for capacity or functions you won't use.

Forever Green Packaging supplies three air cushion machine tiers — Shadow Boxer Mk2, Silver Pack Mk2, and Navy Seal — each running seven or more recycled & recyclable film formats, with no minimum order and free loan machines available for qualifying high-volume businesses.

 

Tom Elgood

Written by Tom Elgood

Founder, Forever Green Packaging — 15+ years in sustainable packaging

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