Fill

Paper Void Fill & Honeycomb Wrap — The Eco Alternative to Bubble Wrap

Paper void fill is the dominant trend in sustainable ecommerce packaging. It's 100% recyclable, performs comparably to bubble wrap for moderate cushioning needs, and reads as premium to eco-conscious buyers. The tradeoff is cost and speed — paper void fill systems are typically more expensive per cubic foot than packing peanuts but cheaper in total cost when you factor in customer perception.

Types of Paper Void Fill & Honeycomb Wrap

Hand-torn paper (kraft roll)

Simple kraft paper rolls torn into sheets and crumpled by hand — the lowest-cost paper void fill option.

Best for: Low-volume packing operations where machine investment isn't justified

Paper dispensing machines (Ranpak, Pregis)

Machine-converts kraft paper rolls into fanfolded, crumpled cushioning on demand.

Best for: Mid-to-high volume fulfillment — reduces packing time and standardizes cushioning quality

Honeycomb kraft wrap

Die-cut kraft paper that unfolds into a hexagonal cellular structure — wraps items like bubble wrap.

Best for: Wrapping individual items that need surface protection with an eco-aesthetic

Shredded kraft paper

Pre-shredded kraft strips used like packing peanuts.

Best for: Void fill and presentation fill in retail/gift packaging

Practical Tips

  • •Paper void fill compresses more than bubble wrap under heavy items — use thicker layers for heavier products
  • •Paper machines (Ranpak GP series, Pregis AutoPad) pay for themselves at 50+ boxes/day through reduced packing time
  • •Honeycomb wrap is more expensive per square foot than bubble wrap but eliminates plastic — factor brand value into the cost comparison
  • •Shredded paper (not shredded documents — purpose-made kraft shred) looks more premium in gift boxes than packing peanuts
  • •For fragile items, paper void fill alone may not provide enough cushioning — pair with foam wrap around the item itself

Frequently asked questions

Is paper void fill as protective as bubble wrap?
For moderate cushioning needs (non-fragile to moderately fragile items), crumpled paper void fill is comparable to bubble wrap. For highly fragile items (glassware, electronics), foam wrap provides better shock absorption than either.
Are paper void fill machines worth the investment?
At 30+ boxes/day, a basic paper machine (Ranpak GP, around $1,500–3,000) typically pays for itself within a few months through labor savings. Below that volume, hand-torn kraft paper is more economical.
What is honeycomb wrap and how do I use it?
Honeycomb wrap is kraft paper with die-cut hexagonal perforations. When you pull the ends, it expands into a cellular cushioning material. Wrap around items the same way you'd use bubble wrap — it holds shape and provides surface and moderate impact protection.

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