The Ultimate Guide to Protective Packaging

Bubble, foam, paper void fill, air cushion, corner protection and inserts, with guidance on which protects best for fragile, heavy and awkward products.

Protective packaging has one job: keep the product away from shock, vibration and compression. Choosing well means fewer damages without paying for protection you do not need.

Understand the three risks

• Shock: drops and impacts. Managed with cushioning that absorbs energy.
• Vibration: long road journeys. Managed with a snug fit so the product cannot move.
• Compression: stacking and palletising. Managed with board grade and layer pads.

The materials and where they fit

• Bubble wrap: light surface protection and general wrapping. Cheap, quick, made from 30% recycled content and recyclable.
• Foam sheet and profile: scratch protection for finished surfaces and glass.
• Foam inserts: exact-fit protection for high value, fragile or dense components.
• Paper void fill: plastic free, recyclable, good for filling irregular gaps.
• Air cushion systems: high volume, very low material weight, fast at the bench.
• Loose fill: awkward shapes and mixed order picking.
• Corner and edge protection: framed items, furniture and palletised loads.
• Layer pads and dividers: multi-item boxes and bottled or glass products.

Matching protection to product

• Fragile and low weight: foam or bubble wrap (30% recycled content, recyclable) plus a snug fitting box.
• Fragile and heavy: foam insert, double wall box, corner protection.
• Awkward shape: profiled foam or a bespoke box with inserts.
• Electronics: anti-static bags, foam support and exact-fit inners.
• Retail ready: printed inner packs and dividers that survive being opened on shelf.

Going plastic free

Paper void fill, honeycomb wrap, corrugated inserts and paper tape now cover most applications that bubble and film used to. They also present better to end customers and simplify recycling messages.

Test before you switch

Pack two units, ship them on your normal route and open them at the far end. It is the cheapest test you will ever run, and we will provide the samples free of charge.