Void fill materials help solve a very common issue in the packaging industry: product damage. However, with the current business landscape shifting to a further sustainable approach, companies that rely on single-use plastic options should start rethinking their packaging and move to more eco-friendly options such as paper air cushions to reinforce their brand commitment and protect both products and planet.
Among rising sustainable paper void fill alternatives, Eco-Paper Air Cushion by BOTTA EcoPackaging is an excellent solution that combines efficiency, reliability and sustainability, guiding businesses operating in the evolving packaging industry and helping them overcome common issues and threats.
What are paper and plastic void fillers in e-commerce shipping?
Paper and plastic box fillers are packaging materials strategically designed to fill empty spaces in boxes or containers, ensuring that products don’t move, collide or break and reach their destination in optimal condition.
Plastic is the most common void fill material, followed by paper and foam, and comes in different shapes:
- Bubble wrap
- Air pillows
Paper has lately become a very appealing option, offering numerous eco-friendly alternatives, unlike non-biodegradable single-use plastic solutions:
- Paper air cushions
- Bubble paper
- Kraft paper
- Crinkle paper
- Honeycomb paper
Lately, the use of void fill packaging has increased with the rise in e-commerce, which accounts for more than 30% of the market share, with air cushions being the fastest-growing product type.
Why is single-use plastic void fill a problem?
Although plastic void fill is widely used globally, it carries many consistent disadvantages that companies must not underestimate.
In peak retail seasons, spanning from October to December, the percentage of global sales grows considerably year by year and with this the need for larger amounts of packaging materials, with plastic being the most popular.
The use of excess plastic packaging spreads across various sectors:
- Food and beverage
- Beauty products and cosmetics
- Retail clothing
- Technology and electronics
- Healthcare
Not only is excessive use of plastic harmful for the environment, but interestingly, at the same time, the number of returns during and after the peak season increases on average by 44.5% compared to the rest of the year, with most orders returned because the product is damaged during shipping.
This connects to another issue concerning plastic void fill: inconsistent protection performance.
Because inflated with air, thin layers of plastic bubble wrap and air cushions are prone to puncture, leaks and deflation when exposed to rough handling. This implies a real risk: if cushions deflate during transit, goods may not have adequate support and could arrive damaged, threatening brand image and reputation.
On the contrary, paper void fill solutions such as paper air cushions are much safer for businesses, their e-commerce and the planet too. This is because, other than being recyclable, paper material is thicker and sturdier than standard bubble wrap or plastic air cushions, therefore less prone to puncture.
Paper air cushions ensure stable protection throughout the whole shipping process, favoring customer satisfaction, key for companies and their profits.
Choosing the right box filler isn’t just about cost or convenience, it’s a strategic business choice.
How does single-use plastic void fill hurt the environment?
While plastic materials are a popular option for many because of their lightweight, flexible and cost-effective protective qualities, their disposal and environmental impact represent a major drawback, especially when consumed excessively in peak retail seasons.
This is because most plastic void fill is made of single-use plastic which is non-biodegradable. Due to waste mismanagement, microplastics can enter the soil, waterways and food chain and become a threat to wildlife and human health, taking hundreds of years to break down.
In fact, products like plastic bubble wrap and air cushions often end up in landfills with general waste, taking 10-1,000 years to degrade completely and often causing serious contamination issues at the recycling plants.
Beyond disposal, production and transportation of plastic void fill add to its relatively high carbon footprint, which primarily originates from:
- Reliance on non-renewable resources like petroleum
- Release of greenhouse gases into the atmosphere
- Consumption of large amounts of energy and water
Why are companies replacing single-use plastic void fill with paper void fill?
Mostly due to its negative impact on the environment, single-use plastic void fill packaging entails numerous challenges and threats; this is also why governments are introducing stringent regulations to curb plastic pollution and promote eco-friendly solutions such as EPR (Extended Producer Responsibility) and PPWR (Packaging and Packaging Waste Regulation).
Such policies are pushing companies towards more sustainable and effective packaging void fill alternatives, such as paper, as awareness of the environmental impact of packaging materials rises globally. Consumers are also increasingly favoring brands that adopt sustainable solutions, like paper air cushions.
Overall, companies can benefit from paper solutions by:
- Reducing carbon emissions and waste
- Obtaining regulatory compliance
- Contributing to a circular economy
- Increasing consumer trust and loyalty
- Enhancing brand image
Changing to more sustainable solutions as soon as possible is vital for companies and will become mandatory when EU regulations’ provisions, like those of PPWR, take effect. Businesses who don’t meet requirements risk fines, product delisting and denied access to markets.
Compliance with EU regulations isn’t a possibility, it’s a must.
Sustainable paper void fill solution: Eco-Paper Air Cushion by BOTTA EcoPackaging
Eco-Paper Air Cushion by BOTTA EcoPackaging is a sustainable on-demand air void fill system designed as an alternative to single-use plastic void fill for e-commerce protection.
This advanced solution helps companies fulfill plastic reduction targets thanks to material rolls available in two sustainable versions:
- Paper-based air cushions
- Home-compostable PLA air cushions
Paper air cushions are in fact ideal for recycling and are also highly effective, catering both sustainability and performance and complying with ESG (Environmental, Social, and Governance) framework and sustainability expectations.
Eco-Paper Air Cushion contributes to waste reduction thanks to its on-demand inflation system. Protective volume is produced via its special air cushion production machine only when needed, decreasing storage space issues of conventional pre-inflated plastic pillows and reducing warehouse footprint. This additionally implies:
- Lower upstream transport volume
- Control of material consumption
- Greater efficiency in the packing cycle
As for product damage risks, this innovative system is optimized for e-commerce and specifically designed to:
- Absorb shocks
- Cushion fragile items
- Maintain the product’s position within the outer box
- Ensure lightness and protection at once
Companies that aim at reducing plastic in their packing operations can choose paper air cushion systems like Eco-Paper Air Cushion without changing packing workflow, actually becoming more sustainable thanks to a paper void fill option that combines all necessities, proving to be the ideal solution for e-commerce packaging.
