Short answer
PaperWave air cushion packaging is plastic-free, certified, award-winning transport protection made from over 80% regrowing resources. The system uses flat paper film rolls that are inflated on demand into lightweight pillows, giving the speed and low weight of an air cushion system without the plastic film. It is a modern paper void fill for the despatch bench.
What PaperWave air cushion packaging is
PaperWave is a paper-based void-fill system that creates air cushions on demand, a paper void fill that performs like an air cushion system but without plastic film. The material starts as a flat roll of paper with sealed chambers. A compact machine feeds the roll, inflates each chamber and seals it, producing a string of lightweight pillows that block and brace products inside a box.
The air cushions are made from 100% recycled paper with a very thin, starch-based compostable sealing layer. The result is a cushion that performs similarly to a plastic air pillow for light to medium loads, but can be recycled through standard paper waste streams.
Certifications and awards
Paperwave air cushion film is FSC® certified, confirming the paper material comes from responsibly managed forests and other controlled sources. The range is also ClimatePartner certified, which calculates, improves and offsets the CO₂ footprint of the product.
- FSC® certified for responsibly sourced paper.
- ClimatePartner certified for carbon footprint calculation and offset.
- PTS certified recyclable by the Paper Technology Foundation in Munich.
- RESY mark and 22PAP according to DIN 6120.
- German Packaging Award 2022.
- SPC Innovator Award 2022.
- WorldStar Packaging Award 2023.
- Sustainability Awards 2023.
Easy disposal by the consumer
Paperwave has a very thin seal layer made of a starch-based compostable film, which has been confirmed not to affect the recyclability of the paper. The product is recyclable by pulping, bears the RESY mark and 22PAP according to DIN 6120.
Paperwave Bio has been certified by the Paper Technology Foundation in Munich (PTS) as recyclable, so it can be disposed of via waste paper. This makes it very easy for the consumer to decide on the correct recycling bin. The material is compostable and even degrades in water if it is mistakenly discarded there.
How modern recycling works for air cushions
With today's repulping technology, the paper and sealant layer are separated during the recycling process. This enables Paperwave air cushion film to be recycled with normal waste paper or bio-compostable waste, depending on the waste stream available.
When Paperwave is the right choice
Paperwave works best where you need high-volume, low-weight void fill and want to remove plastic from the despatch bench. Typical applications include e-commerce fulfilment, subscription boxes, spare parts and any product where the main risk is movement inside the box rather than heavy impact.
It is usually not the first choice for very dense or sharp items, where paper void fill, corrugated inserts or foam give better puncture resistance. For fragile glass or high-value electronics, a combination of wrapping and bracing is usually safer than any single void fill.
Paperwave vs the alternatives
| Void fill type | Best for | Recyclability | Storage |
|---|---|---|---|
| Paperwave air cushions | High-volume, light to medium goods | Widely recyclable as paper | Flat roll, very compact |
| Plastic air cushions | High-volume, moisture resistance needed | Plastic film, check local rules | Flat film, compact |
| Paper void fill | Irregular gaps, general cushioning | Kerbside recyclable | Bulkier than rolls |
| Honeycomb wrap | Fragile items needing wrap and fill | Kerbside recyclable | Rolls, moderate bulk |
| Loose fill chips | Awkward shapes | Often polystyrene or starch; check material | Bags, can settle in transit |
Getting the best results
- Use enough cushions to stop movement in every direction; a product that can shift will still damage itself even with the right fill.
- Pair Paperwave with a right-sized box to cut the volume of fill and the outer shipping size.
- Keep a spare roll on the bench so the operator is not tempted to over-pack with a different material when the roll runs out.
- Test the pack with a real shipment before committing to a full run, especially on fragile or high-value items.
Paperwave air cushions are a practical step towards a plastic-free despatch operation. They give the speed of an on-demand air system with the recyclability of paper, and they work particularly well when the box is built to fit the product rather than the other way around.
Frequently asked questions
- Is PaperWave paper void fill or air cushion packaging?
- It is both. PaperWave is a paper void fill that uses an on-demand air cushion system. Flat paper film rolls are inflated into sealed pillows at the bench, giving the speed and low weight of air cushion packaging without the plastic film. It is kerbside-recyclable as paper.
- Are PaperWave air cushions recyclable?
- Yes. The paper chambers can generally be recycled with cardboard and paper. Paperwave Bio is also PTS certified recyclable and bears the RESY mark and 22PAP.
- Do I need a machine to use Paperwave?
- Yes, Paperwave is inflated on demand using a compact benchtop converter such as the AirBoy nano4 or AirWave 1/2. We can advise on the right machine size for your pack volume and bench layout.
- Can Paperwave replace bubble wrap?
- For many light to medium goods it can replace bubble wrap as void fill. For sharp, very heavy or highly fragile items, wrapping with honeycomb paper or adding corrugated inserts may still be needed.
- Is Paperwave suitable for heavy products?
- It is best for light to medium loads where the risk is movement rather than puncture or heavy impact. Dense engineering parts, glassware and heavy items usually need a stronger combination of board, wrap and bracing.
- What certifications does Paperwave hold?
- Paperwave is FSC® certified, ClimatePartner certified, PTS certified recyclable, and carries the RESY mark. It has also won the German Packaging Award 2022, SPC Innovator Award 2022, WorldStar Packaging Award 2023 and Sustainability Awards 2023.
Think your packaging is bigger than it needs to be?
Send us your product dimensions and we’ll come back with a right-sized option. There is no minimum on stock lines, and bespoke corrugated runs can start from as little as one, but we will advise the most cost efficient run rate depending on size and board grade.
Request a QuoteRelated pages
Subscribe to our blog
One email a month with our latest packaging guides, compliance updates and sector notes. No sales pitches, and you can unsubscribe any time.