Void Fill on Demand: Stop Paying Freight and Rent on Air
Bought-in void fill is mostly air that you pay to ship and then pay to store. Moving to film that is inflated at the packing bench turns a pallet programme into a roll programme: the same protected volume arrives on a fraction of the space and is made only when a carton actually needs it.
Fulfilment centres, 3PL warehouses and factory despatch bays currently buying pre-formed void fill.
Every Stage Where This Usually Goes Wrong
Each stage names the problem first, then what we actually do about it. Nothing here depends on a claim we cannot show you.
Nobody knows how much void fill each carton size actually needs, so the buying decision is made on price per bag rather than cost per carton.
How we solve it. We start from your carton programme and daily parcel count and work out which film widths cover it, so the comparison is cost per carton and not cost per bag.
One cushion format rarely fits every carton, and the wrong format either leaves gaps or wastes film.
How we solve it. Four formats run from the same machine: air pillow for parcel void fill, air bubble film for wrapping, air quilt for layer padding and small tube for tight gaps.
A protective material that works in a specification does not always survive your own handling.
How we solve it. We send film samples in the widths you shortlisted so you can inflate and drop test on your own product before committing.
A machine bought for today's carton mix becomes a constraint when the mix changes.
How we solve it. AWPACK-004 covers film up to 600 mm at 10 m per minute. AWPACK-005 covers 200 mm to 800 mm at 28 m per minute, so one machine spans the full range.
Film made with recycled regrind seals inconsistently and the cushions go soft in the carton.
How we solve it. We extrude from 100% new raw material on our own film blowing line, and sample seals during the sealing run so weak chambers are caught on the line.
Ordering by roll count rather than by container space leads to part-loaded containers.
How we solve it. Roll and carton weights are published by width, so you can calculate container fill before you place the order.
A machine problem at the bench stops the whole packing line and email is too slow.
How we solve it. Send a photo or short video on WhatsApp and we work through it with you. Spare parts come from the same source as the machine.
What Changes After the Switch
- Void fill stops occupying pallet positions in the warehouse
- Cushion volume is decided by the packer at the carton, not by a purchase order months earlier
- Cartons are filled to the actual void, which reduces dimensional weight charges
What This Solution Is Built From
Real catalogue items, not a concept. Each one has its own specification table.
Air Cushion FilmInflatable air bubble bag is a continuous roll of pre-sealed small bubble or small tube film that inflates on demand at the packing bench. Once inflated, it forms a…
View Product
Air Cushion FilmFill air film is a continuous roll of small tube or small bubble air cushion film that is inflated on demand at the packing bench. Once inflated, it forms a…
View Product
Air Cushion FilmSmall tube air cushion film is a continuous roll of pre-sealed, narrow chambers that inflate on demand at the packing bench. Each chamber is sealed separately, so a…
View Product
Air Cushion MachineAWPACK-005 is an industrial air filling machine designed for high-volume production of air cushion film. It runs at 28 m/min, inflates film up to 800 mm wide, and…
View Product
Air Cushion MachineAWPACK-004 Mini Type Air Cushion Machine is a compact, lightweight machine designed for small-scale packaging operations. It runs at 10 m/min and produces both air…
View ProductWhere This Fits Next
Void Fill on Demand Questions
How much space does the change actually free up
The inflated cushion is 99% air and 1% PE film, so what arrives as one 300 m roll leaves the bench as the equivalent of pallets of pre-formed fill.
What happens if the machine breaks down
Keep a small buffer of pre-inflated cushions for the first weeks. Send a photo or video of the fault on WhatsApp and we will work through it with you.
Can we start on one bench before rolling it out
Yes. Most buyers start with one AWPACK-004 on a single bench, confirm the cost per carton, then add machines.
Do we need different film for different cartons
Not necessarily. One width covers a range of cartons. If your mix is wide, AWPACK-005 handles 200 mm to 800 mm on one head.
Start With a Short Call About Void Fill on Demand
Send your current pack, your volumes and the constraint you are working against. We will tell you where the change pays and where it does not.