Void Fill Cost Calculator — Air Pillows vs Peanuts vs Paper

Calculate void fill cost per shipment. Air pillows, packing peanuts, kraft paper, and foam — compare options by cost per cubic foot and annual spend.

Quick answer: Void fill cost: Air pillows: $0.02–$0.06/fill. Packing peanuts: $0.04–$0.08/fill. Kraft paper: $0.02–$0.04/fill. Foam rolls: $0.05–$0.12/fill. Annual cost for 5,000 shipments/month: $12K–$72K depending on material.

📦 Void Fill & Protective Packaging Cost Calculator

Monthly Shipments Requiring Void Fill

Avg Void Volume Per Shipment (cubic inches)

Primary Void Fill Material

Material Cost Per Cubic Foot ($)

Labour Per Shipment (seconds)

Labour Rate ($/hr)

Annual Void Fill Cost

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Material Per Shipment

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Total Per Shipment

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How to Use This Calculator

Measure average void volume — the unused cubic inches in a typical packed box — usually 20–40% of box volume.
Select material type — auto-fills typical cost per cubic foot. Adjust for your supplier pricing.
Include labour time — applying void fill takes 8–20 seconds — this often exceeds material cost at scale.

Worked Example

5,000 shipments/month, 150 cu in void, air pillows $0.18/cu ft, 12 sec labour at $18/hr.

Void volume: 150 ÷ 1,728 = 0.087 cu ft
Material/shipment: $0.0156
Labour/shipment: $0.0600
Total/shipment: $0.0756
Annual: $4,536

Labour (79% of cost) dominates over material. Right-sizing cartons to reduce void is a double win: lower void fill cost AND lower DIM weight on parcel shipments. Run the box sizing calculator to find optimal carton dimensions.

Frequently Asked Questions

Kraft paper: 100% recyclable, biodegradable, customer-friendly. Air pillows: recyclable at drop-off points (not curbside), very lightweight. Packing peanuts: biodegradable if starch-based (look for "EPS-free" on label), recyclable at shipping stores. Foam: least sustainable. Many large shippers have eliminated foam entirely and shifted to kraft paper systems.

Right-size cartons (use a box sizing calculator — smaller boxes need less fill). Use product bundles or inserts to fill space. Switch to mailers or poly bags where product allows. Use automated void fill machines (air pillow machines) for consistent fill amounts. Audit your top 10 skus for over-boxing — often 20–40% reduction in void possible.