Can You Use Bubble Wrap to Fill Empty Space in a Box?

If a shipping box is significantly larger than the product inside, one common solution is to add more bubble wrap until the empty space is filled.

But is this the right way to pack a product?

Yes, bubble wrap can be used to fill small amounts of empty space. However, if the box is much larger than the product, choosing a better-fitting box may be more efficient than filling a large volume with additional bubble wrap.

The main objective is to prevent excessive product movement while providing sufficient cushioning against impact.

Why Is Too Much Empty Space Inside a Box a Problem?

A product with too much room to move can slide from one side of the box to another during transportation.

Even if the product itself has been wrapped in bubble wrap, repeated movement can cause it to hit the walls of the box or other items packed inside.

Effective packaging therefore needs to perform two functions:

Cushion the product against impact and limit unnecessary movement inside the package.

Can Bubble Wrap Be Used as Void Fill?

Yes, particularly when the empty space is relatively small.

Bubble wrap can be wrapped around the product or folded and positioned along the sides, top, or bottom of a box.

However, businesses should also consider how much bubble wrap is being consumed per order. Using unnecessarily wide material can create additional waste.

Read: How to Choose the Right Bubble Wrap Width & Reduce Packaging Costs

What If the Box Is Much Larger Than the Product?

If a large amount of bubble wrap is required simply to fill the box, check the box size first.

For example, placing a 15 cm-wide product inside a 40 cm-wide box creates a large amount of unused space.

Filling all of that space with cushioning material may work, but it may also increase packaging material consumption unnecessarily.

For businesses processing hundreds or thousands of orders, even a small amount of excess packaging per shipment can accumulate into a significant monthly cost.

Do Small Products Always Need a Box?

No.

Products that do not require rigid protection from compression may sometimes be packed in bubble mailers instead.

Because the cushioning layer is already integrated into the mailer, businesses may be able to reduce several packing steps.

If you are considering replacing boxes with padded mailers for some SKUs, read: Do Small Items Need a Box? When Can You Use a Bubble Mailer Instead?

What About Products That Need to Stay Visible?

For fulfillment, kitting, SKU inspection, or internal packing processes, visibility can be important.

Clear bubble bags allow employees to see the contents while providing a cushioning layer around the product.

This can be particularly useful when businesses repeatedly pack the same SKUs and want to reduce measuring, cutting, wrapping, and taping.

Related guide: How Can Clear Bubble Bags Save Packing Time and Packaging Costs?

How Can You Tell Whether the Product Is Moving Too Much?

Use a simple shake test.

After packing, close the box and gently move it.

If the product noticeably slides from one side to another, identify where the empty space remains and add cushioning specifically to those areas.

Avoid overfilling the package, particularly with fragile products. Restricting movement does not mean compressing the product as tightly as possible.

Frequently Asked Questions

Can bubble wrap replace other void-fill materials?

Yes, particularly for small gaps. However, if a large amount is needed simply to fill an oversized box, changing the box size or using another appropriate void-fill solution may be more efficient.

Does using more bubble wrap always provide better protection?

No. Protection depends on product weight, fragility, shape, packaging design, and transportation conditions—not simply the number of bubble wrap layers.

Why can a bubble-wrapped product still arrive damaged?

One possible reason is excessive movement inside the box. A wrapped product can still hit the box walls or other products during transportation.

Should a small product use a box or bubble mailer?

A bubble mailer may be appropriate when the product does not require rigid protection against crushing. Fragile or easily deformed products may require a box.

How can businesses reduce packaging cost per order?

Evaluate package dimensions, material usage per item, tape consumption, and packing time together rather than considering only the purchase price of one packaging material.

Summary

Bubble wrap can be used to fill small amounts of empty space in a shipping box.

However, if a box is substantially larger than the product, reconsidering the box size may reduce unnecessary material usage.

For high-volume E-commerce operations, optimizing the relationship between product size, package size, cushioning material, and packing time can help reduce overall packaging cost per order.

Packbros | Konos Industry Co., Ltd.
Bubble Wrap • Bubble Mailers • Clear Bubble Bags
For E-commerce businesses, warehouses, fulfillment centers, and B2B packaging operations.