Sustainable filling material

Sustainable filling material: 

Environmentally friendly packaging solutions for responsible shipping

The parcel market is still booming. According to calculations by management consultants McKinsey & Company from 2022, every German will receive 50 parcels per capita by 2026. Several million parcels will be sent every day, and the trend is rising. In times of growing environmental responsibility, it is no longer enough to simply make the product sustainable - the packaging also plays a key role. This means that the question of environmentally friendly packaging solutions, especially for e-commerce, is increasingly coming into focus. The filling material for parcels in particular plays a decisive role here - because this is where a large ecological footprint is often hidden.

This article sheds light on why sustainable filling material is more important today than ever, what innovative solutions are available and how modern companies can not only protect the environment with environmentally friendly packaging materials, but also delight their customers.

Table of contents

1. The problems of conventional filling materials
2. What makes filling material sustainable?
3. Innovative sustainable filling materials from buhl-paperform
4. Comparison: sustainable vs. conventional filling material
5. Practical tips for switching to sustainable filling material
6. Conclusion
7. Frequently asked questions

The problem of conventional filling materials

The boom in online retail has led to an enormous increase in packaging waste - especially since the coronavirus pandemic. According to the Conversio study ‘Stoffstrombild Kunststoffe in Deutschland’, which was published in 2024, plastic waste from packaging more than doubled between the mid-1990s and 2023 (BKV GmbH, 2023). A significant proportion of this is accounted for by packaging and therefore also by filling material for cardboard boxes. Conventional materials such as polystyrene chips, plastic air cushions or foam cause several problems: 

• Environmental impact: most conventional filling materials are based on crude oil, a non-renewable raw material.
• Long degradation times: Plastic-based materials often take hundreds of years to decompose in nature.
• Difficult to recycle: Many conventional filling materials can only be recycled at great expense or not at all.
• Microplastic problem: Microplastic particles are produced during decomposition and end up in the environment.
• Resource consumption: Production is energy and resource intensive.

In addition, consumers' environmental awareness is constantly evolving. Studies show that consumers increasingly value environmentally friendly packaging solutions and are willing to switch to brands that offer more environmentally friendly alternatives. Recovered paper, and therefore also moulded fibre, meets these requirements and helps to satisfy consumers' growing demands for sustainable packaging.

Legislation such as the EU's Packaging and Packaging Waste Regulation (PPWR) or the EU's Deforestation Regulation (EUDR) is also increasing the pressure on companies to implement more sustainable solutions.

What makes filling material sustainable?

Before we look at the specific solutions, it is important to understand what constitutes sustainable filling material in the first place. The following criteria play a key role here:

Sustainability criteria for filling material:

1. raw materials used

• Recycled materials and waste paper
• Renewable raw materials instead of fossil resources

• Resource-saving production

2. environmental compatibility

• Biodegradability
• Compostable

• Free from harmful substances and chemicals

3. recyclability

• Easy to recycle
• Reusability

• Integration into existing material cycles

4. product life cycle

• Energy efficiency in production
• Low CO2 production chain
• Regional production for short transport routes

Ideally, sustainable filling material for packaging should fulfil all or at least most of these criteria in order to be considered an environmentally friendly packaging material.

Innovative sustainable filling materials from buhl-paperform

As a leading provider of ecological, individual packaging solutions made of fibre castings, buhl-paperform has developed a range of innovative express molded fiber products that serve as sustainable filling material for cardboard boxes, offer optimum product protection, are suitable for many transport situations and are cost-effective and immediately available. These solutions offer an environmentally friendly alternative to conventional plastic filling materials and are made from up to 100% recycled paper.

SafePac - Flexible cushioning mats for void filling

SafePac cushioning mats are the ideal solution when it comes to flexible and customisable filling material for parcels. SafePac combines over 25 years of development and manufacturing experience and offers an excellent alternative to conventional bubble wrap and plastic void fill. The products in the SafePac family adapt perfectly to the contours of the goods being shipped, providing reliable protection for a wide range of products.

The SafePac product family consists of three variants that are optimised for different applications:

SafePac SOFT

Our SafePac SOFT cushioning mats are the ideal solution for sensitive products that require particularly gentle cushioning. The soft, flexible mats offer optimum cushioning for sensitive goods.

SafePac BASIC/STRONG

• SafePac BASIC is the cost-effective all-rounder for efficient order picking processes with a test load of 8,000 kg/m² with 10 mm cushioning distance. This versatile cushioning mat can be used as a flat intermediate layer, as an envelope, as protection for corners and edges or even in an L or U shape.
• SafePac STRONG is the unshakeable protector for heavy loads with an impressive test load of 15,000 kg/m² with 10 mm damping travel. This variant is perfect for the safe transport of heavy products and offers maximum stability.

SafePac FLEX

The flexible all-rounder that moulds itself three-dimensionally to any packaged goods. This highly flexible moulded fibre mat enables the contour-adapted fixation of a wide variety of products without cost-intensive development costs. The SafePac FLEX cushioning mat is an environmentally friendly alternative to packaging foam. Simply press the packaged goods into the tray and the pyramid-shaped cones mould themselves accordingly.  
 

Main features of all SafePac variants:

• Flexible adaptation to a wide range of product shapes
• Excellent shock absorption thanks to patented spring effect
• Easy handling during packaging without additional adhesives
• Space-saving storage thanks to nestability
• Versatile application options for a wide range of products

ReadyFill - packaging chips made from cast fibre

When it comes to loose filling material for parcels, ReadyFill packaging chips offer a sustainable alternative to conventional polystyrene chips. This innovative solution for environmentally friendly packaging material is of course also made from up to 100% recycled paper and ensures optimum protection during shipping. The special design of ReadyFill ensures that the padding material is evenly distributed in the box and provides reliable all-round protection. Just like conventional filling materials, ReadyFill effectively prevents:

• Movement in the carton
• Contact with the packaging walls
• Damage due to impact

Key features of ReadyFill:

• Easy handling and pourable for maximum flexibility
• Excellent product fixation and shock absorption
• Electrostatic neutral, due to natural non-conductivity
• Low net weight reduces shipping costs
• Can be used universally as a parcel filling material or for cushioning sensitive products
   

ReadyFill is also available with additional corrosion protection +corro: the VCI active ingredient guarantees protection during the entire transport process. The ideal rust protection for metal parts.

GlassPac - protective padding for glass bottles

GlassPac is a natural protective packaging specially developed for the safe transport of glass bottles. The pads consist of an upper and lower part, which together form a robust protective layer.
 

Key features of GlassPac:

• UN hazardous goods approval for the safe transport of dangerous goods
• Space-saving due to nestability of the fibre cast parts
• Easy handling thanks to simple insertion of the bottles
• Flexible packaging options for different bottle types and screw caps
• Suitable for both manual and fully automated packaging processes

A particular highlight is GlassPac +liqui, a patented solution with additional protection provided by vermiculite, which ensures increased absorbency.

BucPac® - reliable protection for buckets and cans

BucPac® bucket protection pad is an innovative packaging solution for the individual dispatch of pails and cans. The special padding set was developed to minimise transport damage, speed up the packing process and pack products in a more environmentally friendly way. 

Key features of BucPac:

• Over 1600 different pail and can sizes can be securely packed with just 10 universal padding sets
• Space-saving design significantly reduces storage volume and transport space
• Patented design prevents unintentional opening of the lid or bursting of the bucket during shipping
• Three-dimensional design makes incorrect packaging impossible and guarantees safe use

BucPac® offers a resource-saving solution for the individual dispatch of buckets and cans for a wide range of industries with all kinds of contents, including:

1. Agricultural chemicals (fertilisers, pesticides, etc.)
2. Building materials (adhesives, plasters, mortar, etc.)
3. Food (spices, oils, baking ingredients, etc.)
4. Paints and varnishes
5. Pharmaceuticals and cosmetics
6. Pet food
7. Industrial and petrochemicals

All buhl-paperform products combine sustainable filling material for cardboard boxes with optimum product protection and easy handling. They are the ideal choice for companies that want to make their packaging processes more environmentally friendly and efficient without compromising on product protection.

Conventional vs. sustainable filling material from buhl-paperform in comparison 

To illustrate the advantages of sustainable package filling material, it is worth comparing it directly with conventional solutions:

Life cycle assessment of environmentally friendly filling material for packages from buhl-paperform

The environmental benefits of sustainable parcel filling material are impressive:

• Conservation of resources: using up to 100% recycled paper conserves natural resources.
• Recyclability: buhl-paperform products can easily be returned to the recycling loop. Find out more here.
• Less waste: Complete biodegradability and recyclability reduces the amount of waste.
• No microplastic pollution: In contrast to plastic alternatives, no microplastic particles are produced.
• Responsible action: buhl-paperform's work is based on recycling, renewable raw materials and environmentally conscious action.

Practical tips: How to successfully switch to sustainable filling material

Switching to environmentally friendly packaging material is an important step for any company that takes its ecological responsibility seriously. Here are some practical tips for successful implementation:

1. Conduct an inventory analysis

Before you switch to sustainable filling material for cartons, analyze your current packaging process:

• What products do you ship?
• What protection requirements do these products have?
• How much filling material do you need?
• What are the costs of your current filling material?

2. Plan a test phase

Test the new filling material on a small scale:

• Try different sustainable alternatives
• Carry out shipping tests
• Get feedback from employees and customers

3. Train employees

Ensure a good introduction for your packaging employees:

• Explain how to handle the new material
• Communicate the benefits for the environment and the company
• Provide practical tips for optimal use

4. Use the changeover for marketing

Communicate your sustainability efforts:

• Inform your customers about the environmentally friendly packaging
• Use seals and labels
• Highlight your commitment in your marketing materials

5. Continuous optimization

The transition is an ongoing process:

• Evaluate effectiveness regularly
• Stay open to new developments
• Continuously optimize your packaging process
   

Conclusion

Sustainable filling material is not only an environmentally friendly alternative to conventional solutions, but also an important competitive factor in an increasingly environmentally conscious business world. Buhl-paperform's innovative express molded fiber products - the SafePac product family, ReadyFill packaging chips, GlassPac protective padding and BucPac® bucket protection padding - offer optimal solutions for various applications that perfectly combine product protection and environmental protection.

With almost three decades of development and production experience, buhl-paperform has created packaging solutions that not only impress in terms of sustainability, but also set new standards in terms of functionality and versatility. Made from up to 100% recycled paper, the products are biodegradable, recyclable and, thanks to their innovative design, offer excellent protection for a wide range of goods - from sensitive electronic items and fragile glass bottles to heavy buckets and cans.

By using these sustainable filling materials, companies make an important contribution to environmental protection, meet legal requirements and at the same time strengthen their image with environmentally conscious customers. The initial additional costs are quickly recouped through reduced taxes, optimized warehousing, more efficient packaging processes, positive marketing effects and greater customer satisfaction.
The future of packaging is sustainable - and with buhl-paperform as a competent partner, the changeover is easier than you think. Take the first step towards a more environmentally friendly shipping strategy with the innovative filling materials made of cast fiber.

Arrange a consultation now.

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