Bubble wrap had a good run. But with the UK's Plastic Packaging Tax now at £228.82 per tonne, levied on any plastic packaging with less than 30% recycled content, and EPR (Extended Producer Responsibility) eco-modulation set to penalise non-recyclable materials with surcharges rising up to 100% by 2028, the cost of continuing with plastic void fill is rising on multiple fronts at once.
Add in customer surveys consistently showing that over 60% of UK shoppers judge brands on their packaging choices, alongside the legal requirement to separately collect plastic film across all UK businesses from March 2027, and the direction of travel is clear.
Paper-based void fill and cushioning have caught up. It can protect fragile goods, integrate with automated packing lines and requires no special disposal infrastructure, carrying the kerbside-recyclable credentials that keep your EPR fees lower. Here are 10 options worth knowing about, with a plain-English steer on when to reach for each one.
Why Paper Protection Works
The negative mark against paper void fill has always been that it does not cushion as effectively as plastic foam or bubble wrap. That criticism is increasingly outdated. Modern paper cushioning and void fill formats, particularly hexagonal wrap, two-ply cushioning rolls, and air-pillow paper hybrids, deliver comparable protection for the vast majority of ecommerce product categories at a competitive cost.
All the products below are kerbside-recyclable, and most use 100% recycled content, making them EPR Green or Amber-rated under the Recyclability Assessment Methodology (RAM). That matters to your compliance costs, your Scope 3 emissions reporting, and increasingly to your retail and 3PL clients, who are starting to embed packaging sustainability requirements into their supplier terms.
1. Fanfold Paper Void fill: Bulk Pallet
For high-volume ecommerce hubs and 3PL operations running machine-based void fill, fanfold paper on a pallet base is the format that keeps packing lines moving. The continuous sheet feeds directly into most high-volume dispensing machines, eliminating the loading delays and manual handling that come with roll-based alternatives.
The pallet format itself is the efficiency win: it moves with a standard pallet truck, sits at the machine without any lifting, and the high linear metreage per pallet dramatically reduces changeover frequency during peak periods.
Best for: Large-scale fulfilment and 3PL operations running machine-based void fill.
Choose if: You process high daily order volumes, need to minimise machine downtime, and want a 100% recycled, warehouse-floor-efficient solution.
2. BoxFill™ Dispenser: Machine-Free Void Fill
BoxFill™ is for operations that need effective, scalable void fill without committing to machinery. The paper comes pre-loaded in a dispenser box, pre-crumpled and ready to pull. There are no pre-cut lengths, packers tear off exactly what they need, and no reloading or machine setup.
Because the box is portable and standalone, it works at every packing bench simultaneously, scaling directly with headcount. It uses 100% recycled paper and is fully recyclable, making it straightforward for customers to dispose of correctly. The 65gsm construction gives it solid cushioning performance for standard e-commerce goods.
Best for: Small to medium operations, seasonal volume surges, or multi-bench packing layouts.
Choose if: You want zero capital investment, complete flexibility on deployment, and 100% recycled credentials without any machine dependency.
3. BoxFill™ Hex: Stretchable Hexagonal Void Fill
BoxFill™ Hex takes the same no-machine, dispenser-box approach as the standard BoxFill™, but uses a hexagonally cut paper that stretches as it is dispensed. The stretch means it conforms around irregular shapes and fragile items more naturally than flat paper, offering a more conforming fit around awkward or delicate products.
FSC® certified and 100% recycled, it is particularly well suited to operations packing mixed SKUs where product shapes vary significantly between orders. Like the standard BoxFill™, there are no pre-cut lengths and no machinery costs.
Best for: Mixed SKU operations packing irregular or fragile items that need a wrapping-style fit.
Choose if: Standard flat paper void fill leaves too much movement in the box, and you need something that conforms without requiring individual product wrapping.
4. Contain-a-Pac™: Paper Dunnage Bag
This one operates at a different scale entirely. Paper dunnage bags are designed for load stabilisation inside containers, trailers, and shipping vessels, not for individual parcel cushioning. Inflated between pallets or cargo units, they prevent lateral movement during transit, which is one of the leading causes of damage on longer supply chain journeys.
Made from 100% recycled paper and built to be heavy-duty and reusable, Contain-a-Pac™ bags are a direct plastic-to-paper switch for operations still using poly woven or plastic dunnage bags. It is lightweight for handling and strong enough to brace loaded pallets.
Best for: Distribution centres, logistics providers, exporters, and manufacturers shipping palletised loads by road, sea, or rail.
Choose if: You have pallet movement or in-transit damage issues and need heavy-duty load stabilisation that is recyclable and reusable.
5. grip® PremierPad Multi-fold: Two-Ply Cushioning Roll
The grip® PremierPad system is designed for medium to heavy goods that need genuine cushioning rather than basic void fill. The two-ply, multi-fold paper can be dispensed as flat pads or coiled for wrapping, making it versatile across blocking, bracing, and cushioning applications.
Available in 70gsm for medium products and 120gsm for heavier items, the roll is used with the grip® PremierPad automatic dispenser (programmable for repeat lengths), which brings both consistency and speed to packing operations where the same product ships repeatedly. It is 100% recycled and fully recyclable.
Best for: Operations packing heavier or fragile items, ceramics, electronics, industrial components, which need reliable impact and vibration protection.
Choose if: You need machine-dispensed, programmable cushioning output for consistent protection across high-volume runs of the same product.
6. grip® SuperFlow Fanfold Paper: Machine Consumable
If you are running a grip® SuperFlow Auto or Manual machine, this is the compatible consumable. SuperFlow Fanfold paper is engineered specifically for these machines, producing crumpled paper cushioning consistently and quickly. The fanfold format stores compactly on the machine's dispenser tray and is easy to reload.
Manufactured from 100% recycled content in a natural kraft colour, the paper gives finished parcels a clean, sustainable appearance that aligns with growing customer expectations around responsible packaging. The 360m length per stack means fewer changeovers across a packing shift.
Best for: Operations already using or considering the grip® SuperFlow machine system.
Choose if: You want fast, automated paper void fill production with an eco-credential, 100% recycled consumable that minimises loading downtime.
7. grip® PaperFill: Expanding Void Fill
grip® PaperFill is a 100% recycled, expanding void fill paper that conforms to the shape of products in a box, minimising void space and keeping items from shifting in transit. PaperFill dispenses cleanly, with no dust or residue, which matters in packing environments where product surfaces need to stay clean.
The expanding design means a small amount of paper fills a large volume of void space, making it material efficient as well as lightweight. Its format makes it straightforward to transition staff from plastic bubble wrap, the dispensing motion is familiar, but the output is fully recyclable.
Best for: Ecommerce operations packing multiple items per order where void space varies and items need to be held securely.
Choose if: You want a clean, dust-free paper fill that expands to fill irregular voids, with no machine required and 100% recycled credentials.
8. PAPERplus® Chevron: Stylish Cushioning Paper
AI Image Prompt: Photorealistic, clean white background, an open cardboard box filled with PAPERplus Chevron chevron-cut cushioning paper in brown, white, and black. The distinctive papillon structure is clearly visible. No people. Clean premium product photography.
PAPERplus® Chevron is the choice when presentation matters as much as protection. The Papillon paper structure, a distinctive chevron cut, creates a soft, flexible cushion with a high volume-to-weight ratio, making it effective as both void fill and product wrap for light to medium goods.
Available in brown, white, and black paper offers genuine visual impact at the point of unboxing, which has become a major commercial differentiator for D2C brands. It is 100% recycled, reusable, recyclable, and compostable. The dispensing machine is available on a free-loan or rental basis, keeping the upfront cost of switching low.
Best for: D2C brands, gift retailers, premium product lines, and subscription boxes where the unboxing moment matters.
Choose if: You need protection for light to medium goods and want the void fill itself to enhance brand presentation rather than detract from it.
Which Format Is Right for Your Operation?
The 8 options above cover a wide range of applications, but they fall into three practical categories to help you narrow down the choice:
Machine-based systems (Fanfold Bulk Pallet, grip® PremierPad, grip® SuperFlow Fanfold) are right for medium to high-volume operations where speed and consistency are the priority. The upfront machine requirement is offset by throughput gains and lower per-pack material costs at volume.
Dispenser-box systems (BoxFill™ Dispenser, BoxFill™ Hex, grip® PaperFill) need no machinery at all. They are immediately deployable at any bench, scale directly with your team, and are ideal for variable-volume operations, seasonal surges, or businesses not yet ready to commit to automated void fill.
Wrap and dunnage formats (PAPERplus® Chevron and Contain-a-Pac™ Dunnage Bag) serve specific roles: product-level protection where you would otherwise use bubble wrap, presentation-led void fill for branded unboxing experiences, and heavy-duty pallet stabilisation for logistics and distribution.
If you are not sure which format best fits your current operation, our team is happy to walk through your packing workflow and match the right product to your volumes, product types, and workspace setup.
Explore our full range of paper void fill and protective packaging options.
Note on Machine Systems
Several of the paper consumables listed above work with dedicated dispensing machines available from Allpack. Two machine options are available depending on your volume requirements:
grip® PremierPad Paper Pad Machine, a compact, touchscreen-controlled automatic dispenser for the PremierPad two-ply roll, with programmable length and quantity settings. Suitable for medium-weight product lines running high daily volume.
grip® SuperFlow Auto 2.0 Fanfold Paper Machine, the latest model in the SuperFlow range, built for medium to high-volume environments. Delivers fast, automated paper cushioning with enhanced consistency over the previous generation. Works with SuperFlow Fanfold Paper consumables.
Get In Touch
Ready to transition away from plastic or optimise your existing paper workflows ahead of upcoming regulatory deadlines? Speak to our team about machine options, several are available on free-loan or rental arrangements at qualifying volumes.
Contact the Allpack team directly by emailing us at sales@allpack.uk.com or call us on 01543 396 700 to arrange a workflow audit.