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Void Fill Packaging in Australia: What It Is, Why It Matters & How to Choose the Right Type

Smart packaging choices that protect your products—and your reputation.

Updated: July 2025

Packaging Isn’t Just a Box—It’s What’s Inside That Counts

When you send a product, it’s not only the contents that matter—it’s how well they’re protected in transit. Void fill packaging refers to materials that fill the empty space inside a carton or satchel to keep goods from shifting, breaking, or arriving damaged.

For Australian businesses shipping everything from fragile electronics to household goods, the right void fill strategy ensures safer deliveries, fewer returns, and a better customer experience. It’s also a key part of building a brand that aligns with modern expectations around sustainability.

A Quick Look: What Is Void Fill Used For?

Cushion fragile or irregularly shaped products
Prevent items from rattling or breaking in transit
Improve presentation when unboxing
Support compliance with shipping regulations or courier requirements
Reduce environmental impact (when using sustainable materials)

Common Void Fill Options (and How They’re Used)

Different products require different levels of protection. Below, we unpack some of the most widely used options—along with when and why to choose each.

1. Packing Paper

Simple but effective, kraft paper is widely used in ecommerce and retail. It’s recyclable, biodegradable, and works well for wrapping or cushioning a wide variety of products—from books and gifts to ceramics.

2. Air Pillows

Filled with air and sealed in small sections, these lightweight cushions are perfect for reducing movement in the box. They’re often used in high-volume shipping operations. While made of plastic, many suppliers—including Power Packaging—offer fully recyclable air pillows.

3. Biodegradable Packing Peanuts

Made from starch (usually corn or wheat), these soft fillers can be composted or even dissolved in water. They’re especially useful for filling voids around irregular shapes or multi-item shipments.

4. Bubble Wrap (Standard & Biodegradable)

Still a go-to for highly fragile items like glassware, devices, or instruments, bubble wrap offers high shock resistance. Newer versions use biodegradable plastic blends or are manufactured with recycled content.

How to Choose the Right Void Fill

Fragile items? Bubble wrap or biodegradable peanuts provide the best protection.
Lightweight goods? Air pillows or soft paper void fill work well without adding weight.
Heavier items? Dense paper fill or moulded pulp inserts offer structure and support.
Eco goals? Choose recyclable kraft paper, compostable starch options, or paper-based cushioning systems.
Unboxing appeal? Custom coloured shredded paper or neatly packed void fill creates a more premium experience.

For larger operations, automated paper void fill systems (like Ranpak® or Fill-Air Rocket™) help reduce labour time while maintaining packing consistency.

Real-World Applications: Who Uses Void Fill (and How)

Ecommerce

From boutique skincare brands to electronics stores, ecommerce sellers use void fill to ensure safe delivery and to leave a lasting impression.

Retail Packaging

Retailers often add coloured shredded paper or printed void fill to improve presentation and reinforce brand identity.

Electronics

High-value electronics need anti-static and shock-absorbing protection—void fill systems with bubble wrap and air cushions are commonly used here.

Moving & Relocation

Packing paper and peanuts help protect a variety of household items when used for void fill in moving boxes.

Industrial & Heavy Goods

For heavier or oddly shaped parts, dense paper void fill or custom pulp moulded inserts are typically used to prevent shifting or load damage.

Trends and Innovations in Void Fill

Australian businesses are increasingly turning to paper-based systems, compostable fillers, and automated machines to reduce plastic waste and labour costs. We're also seeing a rise in FSC®-certified paper solutions, reusable packaging formats, and custom branding for enhanced customer experience.

In line with Australian Packaging Covenant Organisation (APCO) guidelines and state-led sustainability targets, many businesses are reviewing their packaging mix—and void fill is often the lowest-hanging fruit for improvement.

Frequently Asked Questions

Is biodegradable void fill actually compostable in Australia?: Yes—products made from natural starch or kraft paper typically meet AS 5810 (home compostable) or AS 4736 (industrial compostable) standards.
Which void fill is best for fragile shipping?: Bubble wrap or biodegradable peanuts work best. Paper fill also performs well when packed tightly.
Can I automate void fill?: Absolutely. We offer systems like Ranpak F1 and Fill-Air Rocket for paper and air-based void fill automation.
Is paper better than plastic?: In most cases, yes—especially if it’s FSC-certified and recyclable through curbside programs. But lightweight plastics like air pillows may be more carbon-efficient in specific freight applications.

Let’s Build a Better Packaging Strategy

At Power Packaging, we’ve helped hundreds of Australian businesses—from national retailers to niche ecommerce brands—upgrade their packaging processes with cost-effective, sustainable void fill solutions.

Want a sample or product recommendation?
Need help automating your packing line?
Curious about compostable vs recyclable options?

We’re here to help. Our local consultants can guide you through selecting the right fit based on your products, volume, and goals.

Speak to a Void Fill Specialist

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