5 types of protective packaging used to reduce damaged returns

Whether shipping delicate electronics, valuable artwork, or everyday consumer goods, the right protective packaging ensures that products arrive as expected and customers remain happy.

Damaged returns not only lead to increased costs and logistical challenges but can also harm a company’s reputation and customer loyalty. Therefore, in today’s competitive market, investing in quality protective packaging is essential for maintaining a competitive edge.

Here, we explore five common types of protective packaging that can significantly reduce the risk of damage during shipping.

1. Foam inserts

Foam inserts are custom-moulded pieces made from materials like polyethylene or polyurethane that provide tailored protection for products during transit. These inserts are designed to fit the exact shape of the items they protect, ensuring stability and preventing unwanted movement.

Benefits of foam inserts

• Custom fit: Foam inserts can be moulded to the specific dimensions of products, providing a snug fit that minimises movement for maximum protection.
• Shock absorption: Effectively absorbing impacts and vibrations, foam inserts protect fragile items from damage extremely well.
• Versatility: Suitable for a wide range of products, including electronics, medical devices, and delicate glassware.
• Professional appearance: Enhances the unboxing experience with a clean and organised presentation.
• Thermal insulation: Some foam types offer protection against temperature fluctuations.
• Lightweight: Adds minimal weight to packages, helping to control shipping costs.

Alternative to foam inserts: Bespoke cardboard packaging

While foam inserts are commonly used for custom-fit protection, bespoke cardboard packaging offers a more sustainable alternative. This option uses carton board or cardboard to create tailored protective solutions using less material.

Benefits of bespoke cardboard packaging include:

• Custom fit: Can be designed to the specific dimensions of products, providing a snug fit that minimises movement and material usage.
• Sustainable material: Made from recyclable and biodegradable cardboard, reducing environmental impact.
• Versatility: Suitable for a wide range of products, from electronics to fragile items.
• Professional appearance: Enhances the unboxing experience with a clean and organised presentation.
• Lightweight: Adds minimal weight to packages, helping to control shipping costs.
• Long-term benefits: Easily recyclable and biodegradable, contributing to a more sustainable product lifecycle.

2. Bubble wrap

Bubble wrap is a widely recognised protective material made from plastic sheets filled with air pockets. Invented in 1957, bubble wrap is still commonly used for wrapping fragile items due to its cushioning properties, versatility and cost.

Benefits of bubble wrap

• Cushioning: Provides excellent protection against impacts and shocks during transit.
• Flexibility: Easily conforms to various shapes and sizes of products.
• Cost-effective: Generally less expensive than other protective materials.
• Lightweight: Does not significantly add to shipping weight.
• Reusable: Can often be reused multiple times, reducing waste.
• Water-resistant: Offers some protection against moisture.

Alternative to bubble wrap: Honeycomb paper wrap

Honeycomb paper wrap is an eco-friendly option that offers similar cushioning properties to traditional bubble wrap, whilst offering sustainability.

Although bubble wrap remains a popular choice for many businesses due to its proven effectiveness and familiarity, honeycomb paper wrap is gaining traction as consumers become more environmentally conscious. It offers a balance between protection and sustainability, making it an attractive option for those looking to reduce their environmental impact without compromising on product safety during shipping and storage.

3. Paper void fill

Paper void fill is an increasingly popular eco-friendly packaging solution used to fill empty spaces in packages. This versatile material can be crumpled, shredded, or moulded to create effective cushioning around products during transit. As businesses and consumers become more environmentally conscious of their footprints, paper void fill has emerged as a sustainable alternative to plastic-based cushioning such as air pillows.

Benefits of paper void fill

• Sustainable option: Made from recycled paper, making it an environmentally friendly choice.
• Versatile use: Can be used for various products and shapes by adjusting the amount of paper used.
• Cost-effective: Generally less expensive than many plastic-based options while providing adequate protection.
• Easy to use: Simple to crumple or shred for immediate use when packing items.

4. Edge protectors

Edge protectors are simple, yet effective packaging components designed to reinforce the corners and edges of packages - typically the most vulnerable areas during transport, handling, and storage. These small devices play a crucial role in preventing damage to shipped goods, especially for heavy or unique shaped items.

Types of edge protectors

• L-Shaped protectors: The most common type, providing protection for two adjacent sides of a package.
• U-Shaped protectors: Cover three sides of an edge, offering more comprehensive protection.
• Full-length edge boards: Extend along the entire length of a package's edge.
• Corner posts: Specifically designed to protect the vertical corners of packages.
• Foam edge protectors: Made from foam materials for additional cushioning.

Benefits of edge protectors

• Improved stacking strength: Enhances the package's ability to withstand stacking pressures during shipping and warehousing. This is particularly important for palletised loads.
• Impact resistance: Helps absorb shocks that could otherwise damage edges or corners, protecting the integrity of both the packaging and the contents.
• Recyclable material options: Many edge protectors are made from recyclable materials such as cardboard or recycled plastics, aligning with sustainability goals.
• Versatility: Can be used with various package types and sizes, from small boxes to large crates.
• Easy application: Generally simple to apply, either manually or with automated systems in high-volume operations.

5. Protective sleeving

Protective sleeving, also known as net sleeving or mesh sleeving, is a versatile and durable packaging solution designed to protect fragile and irregularly shaped items from damage during transport and storage.

This type of protection is particularly useful for products that may rub against each other and cause surface damage.

Benefits of protective sleeving

• Flexibility: Made from flexible plastic or foam, net sleeving conforms to the shape of products, providing a cushioned layer that prevents scratches, abrasions, and impact damage.
• Versatility: Commonly used for glass bottles, ceramics, machine parts, and produce1. It's suitable for a wide range of products with irregular shapes.
• Lightweight and breathable: An ideal packaging choice for industries seeking reliable, reusable, and cost-effective protection for delicate products.
• Easy to use: Simple to apply by hand and can be easily cut to the required length.
• Time-saving: Used in warehouses to save time with otherwise intricate packaging specifications.

Protective packaging solutions from the experts

At Swiftpak, we pride ourselves on delivering the very best protective packaging solutions. With over 45 years of experience and a trusted in-house packaging design team, we can ensure a successful solution that your business deserves.

If you’re interested in making the most out of your packaging, get in touch with our expert team today. We’d love to show you how our packaging experts can help deliver a packaging solution that drives business growth.