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You're done! You've taken care of every aspect of your product, and now you want to ensure that your packages arrive safely and the unpacking experience isn't an unnecessary faux-pas. Fortunately, the world of protective packaging is no longer limited to bubble wrap and plastic airbags.
In this article, we discuss sustainable protective packaging solutions, how to determine when and what kind of protective packaging is right for your business, and more. If you'd rather talk than read, feel free to contact us anytime - we'd be happy to guide you through eco-friendly protective packaging and packaging fillers.
Protective packaging. Air filling. Protective cushions and films. We use these terms to refer to any padding, stuffing or paper you add to your shipping package to protect your goods in transit and/or to create a 'wow' effect for the recipient of your shipment.
But packaging material is more than just 'stuffing' shipping boxes. While air fillers, for example, are largely a solution used in corrugated shipping boxes, they are also often used to enhance the unpacking experience.
There are many different types of interior space fillers and packaging fillers, each unique in their functionality, aesthetics, sustainability and cost. In this article, we describe the different packaging options and share the use cases, pros and cons of each.
Please answer the following questions:
If you answered 'yes' to any of the above questions, fillers should probably be part of your packaging strategy. Unless you are using customized boxes (where there is no such need for filler material), corrugated boxes are the most likely shipping strategy that requires some sort of filler. No matter what your product is, standardized boxes are most likely to contain excess air.
For example, customers who sell hats, shirts, handbags or items that are already packaged in a retail box can order exact custom-sized boxes that fit their specific products. This eliminates the need for fillers.
If you have decided to use protective packaging for your packaging solutions, the next step is to clarify which of the following purposes your protective packaging will serve so you can find the right solution.
Your need for protective packaging typically falls into one or more of the following five categories:
Fragile items should often be individually wrapped in empty packaging before being placed in a shipping box. Wrap each product in sufficient protective layers to protect it from impact (package drop) and from collision with other products in the box. Such packaging will of course protect very well against dust and abrasion.
Gap fillers are best used when you need to keep products in their packaging in place. If you sell several different items and use a box that has extra space inside in addition to the product, you're looking for packaging solutions that fill that space and prevent the contents from moving around in transit.
Some items aren't fragile or irregularly shaped (and can be shipped in a perfectly sized box). However, these items often require edge protection to ensure that any impact on the package does not result in crushed corners and sides.
Padding is also ideal when you are looking for a soft cushioning layer on the bottom and/or top of a shipping container. The padding prevents minor damage to your products in transit and adds an extra layer of protection.
What impression and perception of your brand do you need to create? In this case, the protective and aesthetic functions of the packaging can be combined so that you can communicate the utility value of your product at first impression (e.g. reinforcing protection to demonstrate safety, using colour as part of subliminal psychology).
Padding is also ideal when you are looking for a soft cushioning layer on the bottom and/or top of a shipping container. Padding prevents minor damage to your products in transit and adds an extra layer of protection.
Let's take a look at the options you have when choosing filling agents.
Paper carton fillers are a smart alternative to other fixing packaging materials. They don't have the safe deformation zone of air cushions or bubble wrap, but unlike them, they can save costs and reduce the burden on the environment. For quick packaging, you can try the Paperfix system, which is welcomed by eshops and small goods manufacturers. The paper shred is then created as a by-product of the carton production process, and works in a similar way to crumpled filler paper.
Do you want to wrap elegantly and ecologically? The paper wrap structure ensures sufficient product protection and easily wraps around goods of different sizes and shapes. Simply separate the required wrap length by hand. The use of this paper gift protection makes it ideal for protecting products from damage or scratches.
Try the simple squeeze paper packaging. The roll is wrapped in a paper box for convenient unwinding, which automatically squashes the paper.
Double-strand corrugated board for general use such as interleaving in palletising, wrapping your products, separating products or as an effective protection for products in a box.
'Corrugated board is a paper material consisting of a corrugated layer and one or two smooth layers of paper. It is widely used, especially in the manufacture of cardboard boxes and shipping containers. Both the corrugated and the smooth part of the paperboard are made of boxboard, a paper-like material with a thickness of more than 0.25 mm. Corrugated board is sometimes referred to as corrugated cardboard, although any heavier paper with a higher pulp content can be referred to as cardboard.' Wikipedia states about this material.
Do you make products from glass, ceramics or porcelain? Are your products fragile? Wood wool ideally protects against breakage during transport to the customer. It is often used as a decorative packing filler but is also an effective 'filler' for packing heavy and bulky items. Due to its properties, it is a material that is environmentally friendly and quickly decomposes or can be easily composted.
Ideal material for filling and fixing the interior of boxes. Wood wool has a decorative character. This material is suitable for filling gift packs.
FLO-PAK bodies are a quick and easy filling material that is suitable for manual filling but also for fully automatic dispatch systems. The figure-of-eight shaped bodies are ideal for packing a variety of products or for difficult shapes to be packed with conventional packaging means. The ideal form of disposal of FLO-PAK bodies is incineration in an incinerator. However, if they end their journey in nature, they will completely decompose between 9 and 60 months.
The so-called 'floppaks' have different compositions and colour combinations. They can be made from recycled polystyrene or corn starch by extrusion. Some types may contain decomposition additives and various anti-static additives. In special cases, Flo-pak bodies do not contain flame retardant additives or chlorine (they comply with DIN 51400).
Flo-pak chips (also available as 'floopak without dash) are then transported in bags or boxes in smaller quantities (150l).
Air fillers - cushions are used for placement directly in the packaging. You can have the air cushions delivered already inflated (but this is not recommended due to the unnecessary air transport and cost) or you can easily make them using a machine such as the Activaair in compact dimensions suitable for every packing table. Air cushions provide sufficient protection for different types of product where safety is a concern, e.g. electronics. They help wherever products are sensitive to shocks. By filling the cushions with air directly at your workplace, you have no additional transport costs (minimum weight) and the volume of input material is minimal.
Air cushions are made of HD-PE (High Density Polyethylene, sometimes referred to as High Density Polyethylene) in various sizes and wraps.
Professional palletizing is a science. We'd like to show you some effective ways to use different types of films and liners to secure and secure your goods on the pallet. The most common form of securing is stretch film (either transparent or black) with varying percentages of recyclate and different strengths and weights. However, with a roll of film you also need to be aware of the weight of the inner cavity.
Protective edges are the best way to protect the corners of packaged products and the ideal way to fix the pallet unit. They are economical and environmentally friendly. After use, they are reusable or suitable for immediate recycling by selling them off to the recycling collection. They are most often made of rigid cardboard and may have perforations. In case you want to pull the protective edges tightly to the goods, it is advisable to use a binding tape with a protective plastic corner, due to tearing at the point of pulling.
To protect the corners of fragile goods, it is advisable to use polyethylene corners to ensure protection against mechanical damage.
There is probably no general truth on this topic. It's important to define your needs up front and answer the questions that affect the type, price and design of your package. We have mentioned many of these just in the text of this article above.
If you are unsure, consider consulting with a packaging specialist. He or she will be able to advise you correctly whether your packaging fulfils the functions you have defined, saves you money and does not put too much strain on the planet.
Ideally, however, you don't need the inner fillers of the packaging. Therefore, you can calculate your customized state boxes without the need for fillers now.
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