VOID FILL PLANNING
How Much Void Fill Do I Need?
Void fill should stop damaging movement while using only the material needed for the actual empty volume and product geometry.
SHORT ANSWER
Start with the inputs you can verify
Void fill should stop damaging movement while using only the material needed for the actual empty volume and product geometry.
What the estimate means
Carton volume minus product volume is only a starting point because irregular products do not fill a perfect block.
Cushioning, blocking, and void fill solve different problems and should not be treated as interchangeable.
Where estimates go wrong
Run a small pack test before converting a volume estimate into purchase quantities.
Keep the source measurements and assumptions with the result so another person can review or update the estimate later.
A practical workflow
- Estimate the empty packed volume.
- Choose material for restraint, cushioning, or surface protection.
- Pack, shake-test, and inspect a sample before standardising the amount.