Uncovering the True Costs and Sustainable Solutions for Smarter Packaging
When it comes to packaging, most businesses focus on the box, the product, and getting orders out quickly. But there’s a hidden cost that often goes unnoticed: void fill. Whether you use bubble wrap, air pillows, kraft paper, or loose fill, void fill is essential for protecting goods in transit. However, when used inefficiently, or when boxes are the wrong size, wasted space becomes a silent expense that impacts freight, materials, labour, and even customer experience.
At TigerPak, we help businesses across Australia optimize their packaging every day. One of the simplest ways to reduce costs without compromising protection is to rethink your void fill strategy.
The Hidden Costs of Wasted Space
Higher Freight Costs
Freight carriers increasingly charge based on cubic weight, not just physical weight. A lightweight box full of air can cost more to ship than a heavier, well-packed parcel. Even small gaps inside a carton can bump you into a higher freight tier, leading to bigger cartons, higher shipping costs, and less efficiency per pallet or container. Reducing wasted space is one of the fastest ways to lower shipping expenses.
Increased Damages & Returns
Both too much and too little void fill can cause problems. Overfilling makes boxes bulge and weakens their structure, while underfilling allows products to shift and break. Poor void fill setups lead to more product replacements, additional freight for returns, delayed deliveries, and higher operational costs. Optimizing your fill improves protection and reduces your damage rate.
Slower Packing Times
Excessive void fill doesn’t just waste materials, it slows your team down. Bulky or inconsistent materials force packers to spend too long filling boxes, deal with cluttered workstations, and sometimes repack orders. Streamlined packaging means faster fulfilment and cleaner workflows.
Higher Waste Costs
More packaging doesn’t mean better packaging. Excess void fill contributes to higher waste volumes, increased plastic usage, and bigger carbon emissions due to cubic freight. Smarter packaging leads to both cost savings and sustainability wins.
Why Does Wasted Space Happen?
Most businesses waste space because of limited carton size options, using “closest fit” boxes instead of “best fit,” untrained packing methods, outdated void fill materials, or high-volume SKUs that don’t match standard carton dimensions. These small inefficiencies add up to big, unnecessary costs over time.
Smarter Void Fill Strategies
Optimising void fill isn’t about cutting it out entirely, it’s about choosing the right solution for your products and processes. Here’s how to reduce wasted space while maintaining protection:
Audit Your Carton Sizes
Look for products packed in oversized cartons, SKUs that always require extra void fill, and carton sizes that rarely get used. TigerPak stocks over 1 million cartons, giving you more options to match items to the right-sized box.
Upgrade Your Void Fill Materials
Modern systems can significantly reduce material use, storage space, and packing time. Consider kraft paper machines (compact, fast, and recyclable), air pillow systems (lightweight and efficient), or biodegradable loose fill (great for irregular shapes). The right system can cut void fill usage by up to 60%.
Standardize Your Packing Methods
Clear packing guidelines help reduce material waste, improve consistency, speed up fulfilment, and lower damage rates. Even simple training can create big improvements.
Consider Custom Cartons for High-Volume Items
If you have products that never fit standard cartons well, custom boxes may deliver long-term savings through less void fill, lower cubic freight, better protection, and improved presentation. TigerPak can support custom solutions tailored to your product range.
The Bottom Line
Wasted space isn’t just an operational inconvenience, it’s a cost multiplier that affects shipping, materials, labour, sustainability, and customer satisfaction. By rethinking your void fill strategy, you can achieve lower freight costs, reduced packaging spend, faster packing times, fewer damages, and a more efficient, sustainable warehouse.
TigerPak is here to help businesses across Australia optimize their packaging with smarter boxes, better void fill systems, and expert advice.
Ready to optimize your packaging and reduce costs? Contact TigerPak today for a free packaging audit and discover how smarter void fill strategies can transform your supply chain.
Customer Testimonial:
"The customer service team are incredibly knowledgeable. The team go above and beyond to ensure we have the right product we need, not always the product we ask for. Great work TigerPak 10/10."
- Kelly - Melbourne, VIC.