Protective Cushioning Materials: Are You Using the Right On-Demand Cushioning Solution?

Cushioning has one job: to protect products from the shock and vibration encountered in transit.  However, deciding on the right protective cushioning materials for your packaging depends on various factors unique to your operation. Not only must you consider the size, weight, durability or fragility of the item, freight, and packing material costs, but you also must consider the on-demand machine which dispenses the material.

With these factors in mind, let’s compare three common protective cushioning materials to help determine which material can benefit your operation.

1. ON-DEMAND PAPER CUSHIONING

Advantages

Paper’s versatility is beneficial for operations packing a variety of products, such as 3PLs and large warehouses. Paper can be stuffed into corners and molded around odd-shaped products to protect contents from drops, bumps, and vibration during transit.

Further, the type and size of items packed often dictates the cushioning material. For example, paper is often the best choice when packing very small boxes or when packaging sharp items that may puncture air cushions.

For companies that prioritize curbside recyclable packaging, paper is an attractive solution with the availability of recycled, recyclable, and biodegradable paper in single- and two-ply thicknesses.

Considerations

Overusing paper cushioning can diminish its overall environmental and cost benefits. Additionally, paper cushioning may not rebound as effectively as other on-demand packing solutions, potentially affecting its protective cushioning qualities in certain transit scenarios.

When Machinery Makes the Difference

If safety, reliability, and ease of use are top priorities, explore machinery that is specifically designed to boost productivity and output even when used by less experienced and seasonable workers. The easy-to-operate Pregis Easypack® Packmaster™ Pro on-demand paper system delivers a range of lightweight, robust paper cushions. The Packmaster Pro is practically bullet-proof because it virtually never jams and can be easily loaded and ready to go in 30 seconds.

2. ON-DEMAND AIR CUSHIONING

Advantages

To arrive damage-free, some products need additional cushioning. High-pressure on-demand air cushioning is effective in providing a greater level of protection for delicate and fragile items like housewares and electronics throughout the shipping cycle.

While often perceived as costlier than paper, on-demand air cushioning can be more efficient and controlled, particularly for larger cartons. For example, the number of air cushions to be used inside a carton is easier to determine than paper – especially as some packers err on the side of caution and overpack. It’s also easier to instruct workers that X number of air pillows should be packed in X-size cartons for standardization and improved control of packing supplies.

For companies with sustainability goals, it’s important to understand what sustainability means to these organizations. Paper is a good curbside recyclable option, yet if a product requires greater protection, an air inflatable solution may be the more sustainable offering. Air cushioning successfully reduces product damage, minimizing the environmental waste of manufacturing and reshipping a replacement product.

Additionally, innovations in film have led to more sustainable options, such as air cushions made from recycled materials. For example, Pregis AirSpeed® HC Renew hybrid cushioning is made from 30% post-industrial recycled content, and AirSpeed® HC Renew PCR is made from 80% post-consumer recycled content. Today, Pregis is the only manufacturer delivering 80% PCR in a high-pressure air cushioning solution, meaning that companies don’t have to sacrifice sustainability commitments for product protection.

Benefits of Switching from Traditional Bubble Cushion

Bubble cushion in roll stock form is a popular protective product which can be effective for companies with smaller packaging volumes looking for a manual fulfillment solution. However, rolls of pre-inflated bubble take up considerable inventory space. Because air pillows are inflated on-demand at the packing station, the film occupies considerably less truck and warehouse space. In fact, one pallet of hybrid cushioning is equivalent to nearly one-and-a-half truckloads of bubble.

When Machinery Makes the Difference

High-performance air cushioning is created from a high-pressure air cushioning system like the 

Pregis AirSpeed® Ascent™. The Ascent is easy to use and load and incorporates sensors to identify the film and automatically adjust the system settings accordingly. 

The Ascent produces the Pregis Hybrid Cushioning (HC) portfolio, which features a proprietary square pattern that offers more surface area for better shock absorption and robust protection.

3. ON-DEMAND FOAM-IN-PLACE CUSHIONING

If you’re shipping high-value, heavy, or extremely delicate products, you likely require a low to non-existent damage rate. For the ultimate protection, choose an on-demand foam-in-place system. On-demand foam consists of liquid foam components that expand and conform to the shape of the product, preventing any movement during transit. Typical products packed with on-demand foam include high-quality vases and pottery, sensitive medical equipment, and high-dollar automotive and aviation parts. Heavy and fragile products, like this toilet manufacturer, turned to on-demand foam after a 14% damage rate caused hundreds of thousands of dollars in unnecessary costs.

When Machinery Makes the Difference

If looking for a new foam-in-place provider, select a system that can help increase productivity and efficiency. The Pregis IntelliPack® SmartBagger™, for example, offers a robust interface and endless customization options.

With on-demand foam systems, the availability of superior engineering expertise and technical service are as important as the machine and foam materials themselves. Choose a manufacturer who will work with you, test and optimize your packages for your preferred carrier, and help design the most cost-efficient and practical solution. Service is equally important as your operation needs can rely on routine maintenance and technical support.

 Cushioning materials are made to protect your products during transit. With all the factors involved, the “best” cushioning depends on your operation. For additional guidance, ask your packaging distributor or contact Pregis. Our cushioning specialists know the questions to ask to help you find the most effective materials to fit your unique packaging needs.