A Practical Guide to Void Fill Packaging
Void fill keeps products from moving inside a shipping box. If your team uses kraft paper for void fill and you are still using a manual dispenser, consider the time spent pull out and tearing sheets.
A Krexil roll cutter helps by cutting repeatable kraft paper sheets from a roll, so packers do not have to tear or measure paper by hand for every box. Whether you ask the cutter to make a stack of pre-cut sheets or use the Just-In-Time accessory, an automated cutter can help the bottom line.
What Void Fill Needs to Do
- Stop movement: the product should not slide, bounce, or rotate inside the box.
- Cushion impact: the material should absorb normal handling shocks.
- Control material use: the box should be protected without wasting fill.
- Keep the line moving: packers need material ready at the station.
Common Void Fill Materials
| Material | Best Use | Tradeoff |
|---|---|---|
| Kraft paper | Blocking, bracing, wrapping, recyclable fill | Needs sheet prep |
| Air pillows | Large open spaces with lightweight items | Plastic waste, less bracing strength |
| Bubble wrap | Fragile surfaces and cushioning | Bulky storage, plastic disposal |
| Packing peanuts | Irregular shapes | Messy and easy to overuse |
Why Kraft Paper Works Well
Kraft paper can be crumpled, folded, wrapped, or layered. That makes it useful for both cushioning and bracing. It also stores compactly in rolls and is easier for customers to recycle than many plastic fillers.
The workflow improves when common sheet lengths are prepared. Instead of each packer guessing how much paper to pull, a roll cutter provides repeatable control. For, example you might decide that product A needs 3 sheets of 24 x 24 and product B only needs 1. Once you make the decision there's no guessing and no over stuffing resulting in wasted paper use.
How to Use Paper Void Fill
Crumple and Fill
Use crumpled paper to create a base layer, place the product, then fill open space around and above it. The box should pass a gentle shake test with no product movement.
Block and Brace
For heavier items, make denser paper pads and wedge them between the product and the box walls. The goal is to lock the item in place.
Wrap and Protect
Kraft paper can also wrap products before they go into the box. This helps prevent scuffs and gives the shipment a cleaner presentation.
When a Roll Cutter Helps
Consider an automated roll cutter when packers repeatedly prepare paper sheets during the day, when sheet length varies too much by employee, or when pre-cut sheets are desired.
The cutter does not replace packing judgment. It makes the material-prep step faster and more consistent.
Kraft Paper Types for Packaging
- Natural kraft: strong general-purpose paper for wrapping, void fill, and bracing.
- Recycled kraft: useful for sustainability-focused operations and lighter-duty packaging.
- White kraft: cleaner presentation for retail, food, and branded packaging.
- Coated kraft: moisture or grease resistance for selected food and specialty uses.
Related Krexil Resources
For machine selection details, see Paper Roll Cutting Machines. For the product line, see the Krexil paper roll cutter overview.
FAQ
Is paper void fill as effective as plastic?
Yes, when used correctly. Paper is especially effective for blocking and bracing. Air pillows are better for lightweight cushioning across large open spaces.
Can kraft paper reduce packaging storage space?
Often yes. Rolls of kraft paper usually store more compactly than bulky bubble wrap or bags of loose fill.
How do I choose the right sheet length?
Start with common box sizes, run packing tests, and standardize a few sheet lengths so packers are not guessing for every order.