How Much Void Fill Do You Actually Need Per Shipment?

Too little void fill leads to damaged product.

Too much void fill increases material cost, packing time, and dimensional weight.

The goal isn’t to “fill the box.” The goal is to eliminate movement.

Here’s how to determine how much void fill you actually need — without overspending or under-protecting your shipment.

Step 1: Start with Proper Box Sizing

Void fill should compensate for small empty spaces — not oversized packaging.

If you’re shipping a 10” product in a 16” box, you’re forcing yourself to use excessive filler. In that case, the real fix is a better carton size.

If you’re unsure about carton sizing, review:

→ What Size Shipping Box Do You Need?

Right-sizing the box is the single biggest factor in controlling void fill usage.

Step 2: Identify the Protection Level Required

Not all shipments require the same level of cushioning.

Consider:

  • Is the product fragile or rigid?

  • Does it have sharp edges or protrusions?

  • Will it ship parcel (UPS/FedEx) or LTL?

  • Is stacking likely?

  • Does it have retail packaging already?

For light, durable items, minimal void fill may be sufficient.

For fragile items, cushioning must absorb shock — not just fill space.

If your shipment is especially vulnerable, you may also want to review:

→ How to Prevent Damage in Transit: Edge Protection & Dunnage Explained

Step 3: Measure the True Empty Space

A practical method:

  • Place the product inside the correct-sized box.

  • Center it.

  • Measure the gap on all sides.

  • Calculate total open volume.

As a general rule:

  • 1–2 inches of cushioning around fragile items is common for parcel shipments.

  • Heavier items may require denser materials rather than more volume.

  • Rigid products may only need corner stabilization.

Remember: You are trying to prevent movement — not compress the product.

How Different Void Fill Materials Affect Quantity

Your material choice directly impacts how much you’ll use per shipment.

Paper Void Fill

  • Requires more volume

  • Adds some weight

  • Provides good cushioning when properly packed

  • Ideal for eco-conscious brands

Air Pillows

  • Takes up space with minimal weight

  • Excellent for blocking and bracing

  • Not ideal for heavy items

If you’re comparing material types, see:

→ Paper Void Fill vs. Air Pillows: What’s More Cost-Effective?

Material selection can reduce usage by 20–40% when optimized properly.

Signs You’re Using Too Much Void Fill

Overuse is common — especially in fast-paced fulfillment operations.

Watch for:

  • Excess material spilling out when the box is opened

  • Product sitting “buried” in filler

  • Increased dimensional weight charges

  • Slower packing speeds

  • Rising material cost per shipment

If you’re seeing higher shipping charges, also review:

→ How to Reduce Dimensional Weight Charges with Flexible Packaging

Reducing box size often reduces void fill more than changing materials.

Signs You’re Using Too Little

Under-protection shows up quickly in damage claims.

Red flags:

  • Product shifts when box is shaken

  • Corners dented or crushed

  • Repeat returns for the same SKU

  • Crushed inner packaging

  • Customer complaints about presentation

Movement is the enemy. If the product can move, it can break.

A Simple Rule of Thumb

For most parcel shipments:

  • Fill all empty space so the product cannot shift

  • Maintain 1–2 inches of cushioning for fragile goods

  • Use denser materials for heavy items instead of excessive volume

  • Match material type to product weight

Void fill should stabilize — not suffocate — the product.

The Cost Perspective

Void fill impacts:

  • Material cost

  • Labor time

  • Shipping weight

  • Dimensional weight

  • Damage rates

  • Customer perception

The most cost-effective approach is rarely “use more.”

It’s:

  • Right-size the box

  • Select the appropriate material

  • Use just enough to eliminate movement

That’s how you control cost without increasing risk.

Need Help Optimizing Your Packaging?

If you’re unsure whether you’re using too much — or too little — void fill, we can help evaluate your shipment profile and recommend adjustments.

Atlas Pallets supplies packaging materials for operations that want to reduce waste, control shipping costs, and prevent damage — without overcomplicating fulfillment.

Request a quote and we’ll help you dial in the right solution for your application.

Request a Quote

Or give us a call at (630) 765-5476.