The Complete Guide to Protective Packaging
THE COMPLETE GUIDE TO
PROTECTIVE PACKAGING
Everything you need to know about wrapping, void fill, mailers, load protection, and corrosion protection for safe shipping and storage.
WHY PROTECTIVE PACKAGING MATTERS
Product damage during shipping is not just a cost of doing business. Every damaged shipment means replacement product, reverse logistics, and a customer who may not order again. Choosing the right protective packaging is one of the most straightforward ways to reduce those costs and protect your reputation.The right materials depend on what you are shipping, how fragile it is, whether it is going into short-term transit or long-term storage, and what environmental conditions it may face along the way. Protective packaging is not one-size-fits-all, and using the wrong type, or not enough, creates failure points before a box ever leaves your facility.
At Benchmark, we help operations across Ohio and the Midwest find the right combination of protective packaging for their specific needs, from light retail goods to heavy industrial parts.
Bubble | Foam | Pouches
VOID FILL
Air Pillows | Peanuts | Paper Wadding
READY TO SHIP
Mailers | Bags | Tubes
ELECTRONICS (USE ANTI-STATIC)
Bubble | Foam | Peanuts
METAL PARTS
VCI Paper | VCI Poly Bags
HOW PROTECTIVE PACKAGING WORKS AS A SYSTEM
Most well-protected shipments use more than one type of material working together. Think of it in layers:WRAP OR CUSHION THE ITEM DIRECTLY
This is the material in contact with the product: bubble rolls, foam, kraft paper, or foam pouches. It absorbs impact and prevents surface damage.
FILL THE REMAINING VOID SPACE
Any empty space inside the box allows the item to shift and impact the box walls during transit. Air pillows, packing peanuts, or crumpled paper lock the item in place.
CHOOSE THE RIGHT OUTER BOX
Protective packaging only works as well as the box around it. See our Corrugated Boxes Guide for help selecting the right box strength for your load.
ADDRESS ENVIRONMENTAL THREATS
Moisture, humidity, dust, and corrosion are separate from physical impact. Materials like VCI packaging, pallet covers, and desiccants address these threats independently.
WRAPPING & CUSHIONING
Wrapping materials go directly around the product to absorb shock, prevent scratching, and keep items from shifting inside the box. The right choice depends on how fragile the item is, whether it has sharp edges, and whether moisture resistance matters.
Kraft paper is a strong, tear-resistant wrap available in sheets, rolls, and center-pull rolls. Paper dispensers like the HoneyPack BuzzPro line streamline high-volume use.
BEST FOR
Wrapping | General Cushioning
Irregular Shapes | Interleaving
Bubble rolls are LDPE film with air-filled bubbles that absorb shock and vibration, available in assorted sizes. Also available as bubble pouches for quick individual item protection.
BEST FOR
Fragile Items | Glassware
Ceramics | Instruments
Foam rolls and sheets provide firm, moisture-resistant cushioning for heavy or precision parts; foam pouches are open-ended sleeves for faster protection of individual items.
BEST FOR
Heavy or Industrial Parts
Precision Components
Kraft paper wadding is a multi-ply (up to 10-ply) layered kraft paper available in perforated, slit rolls that provides more cushioning than a single sheet of kraft paper.
BEST FOR
Extra Cushioning
Eco-Friendly Packaging
NEWSPRINT
Newsprint is a lightweight, ink-free paper for wrapping and interleaving non-fragile items at low cost.
BEST FOR
Non-Fragile Items | Interleaving
Light Cushioning
BUTCHER PAPER
Butcher paper is a durable, absorbent paper roll used for wrapping and interleaving where an absorbent paper layer is needed.
BEST FOR
Wrapping | Interleaving
Where Absorbency Matters
CORRUGATED SHEETS & ROLLS
Corrugated sheets and rolls provide a rigid cushioning and separation layer used as pads, wrapping, or dividers.
BEST FOR
Layer Separation | Structure
Rigid Items
ANTI-STATIC PROTECTION
Anti-static products use a pink static-dissipating material to safely protect electronics from electrostatic discharge.
BEST FOR
Circuit Boards | PCBs
Electronic Assemblies
VOID FILL
Void fill occupies empty space inside a box to prevent items from shifting during transit. It is not the same as cushioning: void fill stops movement, while cushioning absorbs impact. Many shipments use both. The right void fill depends on box size, volume, storage space, and how messy the material is to work with.
Air pillows inflate on demand from flat film rolls, making them space-efficient void fill. Virgin HDPE, recycled HDPE, 100% recycled LDPE, paper, and plant-based materials are available.
BEST FOR
High-Volume Shipping
Limited Storage Space
Packing peanuts are loose-fill EPS foam pieces that conform around items inside a box. Biodegradable starch-based peanuts are also available and dissolve in water.
BEST FOR
Large Void Spaces
Varied Box Sizes
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Kraft paper wadding can serve as void fill, adding bulk to fill space while remaining fully recyclable, a plastic-free alternative to loose fill.
BEST FOR
Eco-Conscious Operations
Alternative to Plastic
Kraft Paper crumpled into loose bundles is a low-cost, recyclable void fill for non-fragile goods.
BEST FOR
Budget Void Fill
Non-Fragile Shipments
MAILERS & READY-TO-SHIP PACKAGING
Mailers and ready-to-ship packaging eliminate the need for a separate outer box. They are self-contained, lightweight, and designed for direct shipment. Choosing the right mailer depends on how fragile the item is, whether it needs moisture resistance, and what size and shape it is.
Bubble mailers combine a poly or kraft outer shell with a bubble lining for cushioning, available in kraft or poly exterior versions.
BEST FOR
Small Fragile Items | Jewelry
Electronic Accessories | Photos
Poly mailers are lightweight, water-resistant plastic envelopes with a self-seal closure and no cushioning.
BEST FOR
Clothing | Textiles | Documents
Non-Fragile Soft Goods
Mailing tubes are rigid cylindrical containers that protect items that cannot be bent, folded, or compressed during transit.
BEST FOR
Documents | Blueprints
Posters | Long/Cylindrical Items
SELF-SEAL FLAT MAILERS
Flat mailers are rigid or semi-rigid envelopes with a self-seal closure for flat items that must arrive unbent.
BEST FOR
Documents | Photos
Flat Artwork | Certificates
ECO MAILERS
Eco mailers are a sustainable option made from recyclable or compostable materials, offering an eco-friendly alternative to standard poly mailers.
BEST FOR
Eco-Conscious Shipping
Operations Reducing Plastic
INDUSTRIAL MAILERS
Industrial mailers are corrugated mailers that provide structural protection for items that could be damaged by bending or compression in transit.
BEST FOR
Rigid Protection
Crush Resistance
LOAD & SURFACE PROTECTION
Load protection products stabilize, separate, and shield entire loads or surfaces rather than individual items. They are most commonly used in warehouse, pallet, and industrial shipping contexts where bulk product movement is involved.
Slip sheets are chipboard and eco sheet pads used as protective layer separators between stacked products to prevent shifting, scratching, and crushing during storage and transit.
BEST FOR
Separating Stacked Layers
Warehousing & Transit
Dunnage bags are inflatable paper or poly bags placed in the void spaces between cargo loads inside trucks, railcars, or shipping containers to prevent load shift during transit.
BEST FOR
Securing Cargo | Long-Distance
High-Vibration Transit
Corner boards and edge protectors sit between strapping and box edges on palletized loads, distributing strap tension to prevent crush damage and improve stacking stability.
BEST FOR
Palletized Loads with Strapping
Risk of Crush Damage
Poly pallet covers and top sheeting protect loads from moisture, dust, and contamination during outdoor storage or extended staging, complementing stretch film rather than replacing it.
BEST FOR
Outdoor/Dock Storage
Humidity-Sensitive Products
CORROSION PROTECTION
Metal parts and machinery components are highly susceptible to rust and corrosion during shipping and storage. Standard paper and plastic packaging provide no protection against corrosion. VCI (Volatile Corrosion Inhibitor) materials release molecules that form a protective layer on metal surfaces, blocking moisture and oxygen from causing oxidation.VCI PAPER
VCI paper is kraft paper permeated with corrosion-inhibiting compounds, available in sheets and rolls, providing approximately two years of protection when stored correctly.
VCI POLY BAGS
VCI poly bags range from small flat bags for individual parts to large gusseted bags for entire pallets, are transparent for easy content identification, and provide up to three years of protection when properly sealed.
Our VCI Corrosion Protection Guide covers how VCI technology works, compatible metals, shelf life, proper use, and how VCI compares to desiccants.
HOW TO CHOOSE
Use this table as a starting point. Most shipments benefit from more than one type: a wrapping material around the item and a void fill to fill the remaining space in the box.| SITUATION | PRIMARY CHOICE | ADD IF NEEDED | NOTES |
|---|---|---|---|
| Fragile items (glassware, ceramics) | Bubble rolls or foam | Air pillows or kraft paper for void fill | Wrap item directly; fill remaining box space |
| Electronics and circuit boards | Anti-static bubble wrap or anti-static foam | Anti-static void fill | Do not use standard bubble wrap or EPS peanuts |
| High-volume e-commerce packing | Air pillows for void fill | Kraft paper or bubble pouches for wrapping | Fast, low-cost, small storage footprint |
| Heavy or industrial parts | Foam sheets or corrugated sheets | Corner protectors if palletized | Pair with double-wall boxes for maximum protection |
| Metal parts or machinery | VCI paper or VCI poly bags | Desiccants for high-humidity environments | Standard paper and plastic provide no corrosion protection |
| Small items shipping without a box | Bubble mailer or poly mailer | Bubble pouch inside for extra fragile items | Use poly mailers for soft goods; bubble mailers for fragile |
| Documents, posters, or blueprints | Mailing tubes or flat mailers | None typically needed | Tubes for items that cannot be folded; flat mailers for stiff documents |
| Palletized loads in transit | Dunnage bags or slip sheets | Corner protectors and pallet covers | Dunnage bags fill void between loads in truck or container |
| Sustainability priority | Kraft paper or paper wadding | Biodegradable packing peanuts for loose fill | Both are recyclable or compostable |
COMMON QUESTIONS
Answers to the questions we hear most about protective packaging materials.
What is the difference between void fill and cushioning?
Void fill fills empty space inside a box to prevent items from shifting. Cushioning absorbs shock and impact to protect fragile items. Some materials, like crumpled kraft paper, do both. Air pillows are primarily void fill. Foam is primarily cushioning.
Can I use regular bubble wrap for electronics?
No. Standard bubble wrap can generate static electricity that damages circuit boards and sensitive components. Use anti-static bubble wrap for electronics — it looks similar but is made with a static-dissipating material.
How do I know if packing peanuts are biodegradable?
Place one under running water. Starch-based biodegradable peanuts dissolve within seconds. Standard EPS polystyrene peanuts will not change at all.
What is the difference between a bubble mailer and a poly mailer?
Bubble mailers have a bubble-lined interior that cushions fragile items. Poly mailers are plain plastic envelopes with no cushioning, better suited for soft goods like clothing and textiles.
When should I use dunnage bags instead of other void fill?
Dunnage bags are for large void spaces between cargo loads inside trucks, railcars, and shipping containers. Standard void fill like packing peanuts or air pillows is for void space inside individual boxes, not between large cargo units.
Do I need VCI packaging for all metal parts?
Not necessarily. VCI is most important for ferrous metals like steel and iron. For short-term transit in dry conditions, standard packaging may be sufficient. For storage, international shipping, or high-humidity environments, VCI is strongly recommended.
How do I know if I am using enough protective packaging?
After packing, shake the box gently. If the item moves or shifts, you need more void fill. For fragile items, there should be at least one to two inches of cushioning on all sides between the product and the box wall.
Can protective packaging materials be reused?
Many can. Packing peanuts, bubble rolls, foam sheets, and foam pouches that are undamaged can be reused for future shipments. Reusing is the best option for materials that cannot be recycled through standard programs. Air pillow film is single-use once inflated.
How should cushioning materials be stored?
Store foam, bubble rolls, packing peanuts, and paper products in a cool, dry place away from direct sunlight. Avoid stacking heavy items on top of rolls or pre-inflated materials. Air pillow film rolls store flat and are not affected by stacking.
What are the most eco-friendly protective packaging options?
Kraft paper, newsprint, paper wadding, and corrugated sheets are recyclable and biodegradable. Biodegradable starch-based packing peanuts dissolve in water. Benchmark also carries paper-based and corn starch-based air pillow films that are home-compostable or plant-based.
KEEP LEARNING
Explore more packaging guides from Benchmark Industrial.Corrugated Boxes Guide
Flute types, ECT ratings, box styles, and how to choose the right corrugated box for your product.
Hot Melt vs. Acrylic Tape Guide
How to choose the right carton sealing tape for your application, environment, and volume.
Pallet Containment Guide
Stretch film, strapping, edge protection, and pallet covers for securing loads from warehouse to delivery.
VCI Corrosion Protection Guide
How VCI paper, poly bags, and sprays protect metal parts from rust during shipping and storage.
Shop Benchmark's full selection of protective packaging,
or contact us for product recommendations and volume pricing.