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Bubble Wrap vs. Air Pillow Void Fill: Comparing Costs

 

Package contents have never had it so good—today they can ride on air pillows, bubble wrap, and many other cushiony fillers. But which choice of void fill is the best value for the busy shipper? Let’s look at two leading void fill options—bubble cushion wrap and air pillows—and weigh their costs and benefits.

Which Is the Better Value: Bubble Wrap or Air Pillows?

Bubble wrap and air pillows are both popular packaging materials. But which is the better value? A quick review of your applications is crucial for weighing the costs and benefits of these two options. The question comes down to the primary purpose of the filler material: product cushioning and protection or simple void fill?

  • Bubble wrapping is great for protecting fragile objects and for ensuring a pointy object won’t puncture a box, but it is not always the best solution for filling a large void. Cushioning bubble wrap is best used for content protection and for filling smaller voids.
  • Air pillows, on the other hand, are a cost-effective way to fill voids of all sizes. With minimal time and materials, you can fill the void around an object and send the box on its way. When comparing material costs, air pillows simply fill much more space with much less plastic, which lowers overall costs. But air pillows do not offer much protection to a fragile object that does not have its own wrapping and cushioning. They also do not have the strength to provide the bracing required to prevent items from shifting. They are a low-cost void fill option best used when filling space around items that have their own internal packaging or are not prone to damage during shipping.

 

In summary, while bubble wrap is an economical choice for cushioning and protection, air pillows are a more cost-effective solution for basic void fill. Wadding up large quantities of bubble wrap to fill a large void will be more expensive than using air pillows. Air pillows are the most cost-efficient void fill, providing low-weight, low-cost, recyclable filler for your packages.

 

If product protection is an issue, you can always use both—bubble wrap around the product, and air pillows to fill excess space in the box. This may provide a more economical solution than bubble wrap alone.

 

However, there are other factors to consider when making the choice, including start-up costs, productivity, and workflows.

 

What are the start-up costs for air pillows vs. bubble cushioning wrap?

It is important to realize that there are some start-up costs when making the switch to air pillows. This solution requires a machine to create the pillows. After buying the machine (or more than one), you have to train workers to use it. Whether or not this solution is a good value for you really depends on your shipping volume. For businesses consistently shipping many boxes requiring extensive void fill—for example, warehouse fulfillment centers—the air pillow machinery will quickly pay for itself in reduced material costs and increased productivity.

 

But if you are only shipping the occasional box, it might be better to stuff away, using bubble wrap or even more affordable options like kraft paper to fill larger voids. Start-up costs for bubble wrap are negligible, involving nothing more than the cost of the roll itself (and perhaps a stand to hold it).

 

How do bubble wrap and air pillows compare on productivity?

When comparing productivity between bubble wrap and air pillows, air pillows win once again when it comes to filling large voids. Air pillow machines can create large quantities of void fill in seconds. All workers have to do is tear off the number of pillows needed, put them in the package and close. A high-volume packaging operation would no doubt benefit from air pillow machines. They deliver the productivity and cost-effectiveness needed for that situation.

 

Bubble cushioning wrap is more of a manual process. Workers must tear off the correct amount, wrap the item to be protected, and wad up more to fill in any remaining space. This is much more time-consuming than throwing in some pillows. Again, if you need product protection and cushioning, bubble wrap may be the better choice. Pre-perforated bubble sheets can improve productivity.

 

Are there hidden costs for bubble wrap and air pillows?

There are a few other considerations to keep in mind when choosing between bubble cushioning and air pillows.

  • Storage space: Another major advantage of air pillows is how little storage space they require. The air pillows come in a box or roll of plastic sleeves, and these take up minimal space on your shelves. The air pillow machine injects air into the pockets, inflating them into the pillows you know and love. You only produce as many as you need at the moment. Bubble cushioning, on the other hand, comes in large rolls of wrap that occupy a lot of space. Bubble wrap requires frequent resupplying, as well.
  • Maintenance: Air pillows deliver exceptional void fill, but because the technology requires a machine to fill the pillows, it incurs costs that bubble wrap doesn’t. After purchasing the machine and training workers on it, you will also need to service it periodically. This will cost you both time and money. Fortunately, product warranties and service plans can help you keep maintenance costs down.

 

When would bubble wrap or air pillows not be cost-effective or advisable?

While these cushioning and void fill options are usually best, there are a couple of situations that require a different solution. In particular, small and fragile items would best be served by a poly bag or bubble mailer. If your operation handles a lot of objects like this, then a roll of bubble wrap and a good selection of poly bags and bubble mailers would be your best bet.

 

Recent Factors Affecting Cost for Bubble Wrap and Air Pillows

Both bubble wrap and air pillows are made of plastic or resin. Bubble wrap consists of sheets of plastic or resin with small bubbles (the joy of bubble-popping children everywhere), while air pillows consist of clear envelopes that can be inflated with an air pillow machine. These plastics and resins are made of oil-based materials, and their costs roughly follow the price of gasoline: when oil costs go up, these materials go up in cost, as well. Labor shortages and transportation issues resulting from the COVID-19 pandemic are also currently pushing prices upward.

 

These issues may be transient; expect pricing for bubble wrap and air pillows to follow trends in the petroleum and labor markets. As always, Benchmark will work with our suppliers to ensure that you have the best pricing possible for packaging materials.

 

Top Tips for Saving Money on Void Fill

There are some ways you can save money on void fill and packaging materials. Here are a few tips for reducing your packaging material costs.

  • Volume: As with most products, buying in volume will help you save money on either bubble wrap or air pillows. High-volume orders cut down on shipping costs, as well. Discounts you receive on your orders might offset some of the expense.
  • Quality: Look closely at your application and determine the most cost-effective void fill solution. Bubble cushioning comes in many different thicknesses and bubble sizes, and choosing the right one could save you significant money. Air pillow sleeves come in different thicknesses and designs, as well. Make sure you have the level of product protection required for your shipments, but there is no point in buying thicker or more expensive material than you really need.
  • Package size: If your boxes are consistently large, air pillows are likely the best void fill solution for you. Smaller packages might be a better fit for bubble wrap, poly bags, and bubble mailers.

 

The Best Void-Fill Solution Is the Most Informed One

A reliable supplier can help you weigh the pros and cons of your various void fill options. Perhaps it’s time to make the leap to an air pillow machine? Benchmark can walk you through the options. Or maybe you just need to get through the next year with a better bubble wrap. Whatever your needs, Benchmark experts can help.

 

Need help deciding which void fill solution is right for your operation? Talk to one of our product experts.