Eco friendly void fill solutions to protect your products and the planet

When it comes to packaging, even the smallest gap can cause damage to your products. Especially with flat-pack furniture, electronics, or homeware where different-sized components can shift around in transit. The old solution might have been patching up holes with polystyrene, but Dufaylite’s honeycomb void fill proves there’s a better way. Lightweight, strong and adaptable, our void fillers are made from 100% recycled paper and fully recyclable.

Custom eco friendly packaging solutions for every packaging challenge

Whether you need to fill space or add extra strength, honeycomb void fill uses minimal material for maximum impact. The honeycomb structure can be adjusted to provide just the right amount of support, with custom sizes available for every packaging requirement. It’s the smarter, greener choice that’s easy to recycle and tough where it counts.

Why honeycomb void fill is the smart, sustainable packaging choice

PROTECT YOUR PRODUCTS, PROTECT THE PLANET
The best reason to switch to honeycomb void fill? It’s a win for the planet, your business, and your customers. Crafted from 100% recycled paper and fully recyclable, honeycomb void fillers keep materials in the circular economy. This means businesses are protecting their products and meeting sustainability targets.

BETTER PACKAGING, BETTER EXPERIENCES
With honeycomb void fill, you get one clean piece of board. No mess, no hassle, and no polystyrene flying everywhere during unboxing. And because it’s exempt from plastic packaging waste taxes, you save money while helping the planet.

YOUR CUSTOMERS NEED SUSTAINABLE SOLUTIONS
Nobody likes packaging that’s difficult to recycle. Our honeycomb void fillers are easy to dispose of responsibly, creating a better unboxing experience and demonstrating your commitment to a sustainable future. Show your customers you care with packaging that reflects your brand’s values.

MAXIMISE EFFICIENCY, MINIMISE WASTE
Why layer up with corrugated card when honeycomb does the job with a fraction of the material? Using just what’s needed to fill the gaps, our solution outperforms other paper-based options. Less material means less waste, which in turn means less hassle for you.

SPEED UP PACKING LINES WITH HONEYCOMB VOID FILL
Think honeycomb packaging might slow things down? It actually does the opposite. Honeycomb streamlines the packing process. Fewer pieces per box, consistent board thicknesses, and quicker packing times mean a faster, more efficient packing line. It’s all about enhancing efficiency and productivity.

TRANSFORM PACKAGING WITH A GREENER SOLUTION
Switching from EPS to honeycomb isn’t just a swap – it’s a smart rethink of how packaging can work for you. Many businesses have made the change without increasing lifetime costs, proving that thinking outside the box is great… but in our case, thinking inside the box is where the magic happens (pun absolutely intended)!

Dufaylite paper honeycomb void fillers for packaging

Collaborate with the design lab for custom solutions

Optimise your eco friendly packaging with our in-house Design Lab. We provide custom solutions and innovative designs tailored to specific business needs and collaborate with clients to develop smarter, greener packaging that works. Visit the Design Lab for Packaging page to explore bespoke packaging solutions or contact one of our Dufayliters for more information on how to get started.

Who benefits most from honeycomb void fill? Think flat-pack, think e-commerce

For flat-pack furniture – whether it’s kitchens, beds, TV stands, wardrobes, or more – there’s always a void that needs filling. For e-commerce brands, ensuring products arrive safely is crucial to maintaining your bottom line and brand reputation.

Our void fill works perfectly alongside cardboard corner protection and cardboard pallets to provide a complete, secure packaging solution. For a truly tailored approach, consider our bespoke packaging options. Together, these innovative solutions enhance stability and safety during transport, keeping your goods protected from every angle.

Key features for packaging designers

Custom cuts for any void fill need: from compact 30mm x 60mm pieces to larger configurations. Our solution can be tailored to meet any requirement, optimising protection, and efficiency.

Simplified specs, lower MOQs: struggling to manage over 100 SKUs? By working closely with you to redesign your packs using our honeycomb expertise, we help reduce the number of material specs while still delivering all the SKUs you need. With full UK manufacturing and fewer materials, we make those tricky MOQ challenges a breeze!

Paper honeycomb void fill vs polystyrene, plastic and loose fill

Void fill stops your product moving in transit — but most void fill is polystyrene, plastic air pillows or loose fill that the customer can’t recycle at home. Dufaylite’s paper honeycomb void fill is different: engineered, rigid bespoke fitments that hold the product firmly and go straight into the kerbside paper recycling. Here is how the common void fill materials compare.

Void fill type	Kerbside recyclable	Structural protection	Tax & EPR	UK made
Envirolite paper honeycomb void fill	Yes — standard paper stream	High — rigid engineered fitment	Lower EPR, no plastic packaging tax	Yes
Polystyrene (EPS) chips or blocks	No	Low–moderate	Higher EPR	Varies
Air pillows / inflatable plastic	No — not kerbside	Low	Plastic packaging tax applies	Varies
Loose fill / packing peanuts	Rarely	Low	Varies	Varies

Where paper honeycomb void fill is used

Pallet base pads and layer pads for palletised loads
Box liners and fitments that fill space around the product
Corner and edge void fillers and protectors
Filling gaps around heavy or high-value goods in transit
Structural void fill where loose fill would settle or crush

Every void fill solution is engineered and cut to your box and product in the UK — and because the honeycomb is rigid, it won’t settle, migrate or crush the way loose fill can. Envirolite is Carbon Neutral Britain™ certified and FSC certified (C186880), so it gives sustainability teams verified credentials, not vague claims.

What is the best void fill material?

It depends on the goods, but for structural protection combined with recyclability, engineered paper honeycomb void fill outperforms loose fill and air pillows — it holds the product firmly, doesn’t settle or crush in transit, and the customer recycles it kerbside with the box.

Is cardboard void fill recyclable?

Yes. Paper honeycomb void fill is 100% recycled paper and kerbside recyclable in standard paper streams — no specialist collection, unlike EPS chips or plastic air pillows.

Does Dufaylite make honeycomb wrap paper for void fill?

No. Dufaylite makes engineered, structural paper honeycomb void fillers and fitments — not the roll-format honeycomb wrap paper used as loose e-commerce void fill, which is a different product made by other suppliers.

Need void fill that protects and recycles kerbside? Tell us about your product and our design lab will engineer a paper honeycomb solution to fit.

Frequently Asked Questions

What sizes can be cut with honeycomb void fill?

Honeycomb void fill can be cut into a wide range of sizes, from compact 30mm x 60mm pieces to large 4000mm x 1600mm sheets. This packaging optimisation for any box size and product shape reduces wasted space and enhances protection. All cutting and fabrication are completed at a UK-based, carbon-neutral site, ensuring precision, fast lead times, and consistent quality with every order.

How are those small pieces of void fill handled?

Handling small pieces of void fill can be challenging, but Dufaylite provides perfectly sized cardboard shipping boxes that are easy to move, organise, and recycle. Our smart designs fit into the circular economy, balancing practicality with sustainability. For businesses facing specific handling or packaging challenges, the Design Lab can develop bespoke solutions that integrate seamlessly into existing production lines. Learn more about tailored packaging solutions here.

What’s the minimum order quantity for honeycomb void fill?

We want to help all brands, which is why we’re flexible on minimum order quantities. The team works closely with businesses to find the right balance of quantity, material, and cost that fits their needs. With in-house manufacturing capabilities and extensive experience in custom packaging, Dufaylite focuses on innovative ways to adjust material specifications and minimise MOQs without compromising on quality or sustainability.

Are honeycomb void fillers FSC Certified?

Yes, they are all FSC certified, meaning they are sourced responsibly from well-managed forests. Dufaylite’s certification number is C186880. This certification helps businesses meet environmental standards and reinforces a commitment to sustainability.

Is everything made in the UK?

Dufaylite manufactures paper honeycomb at its Carbon Neutral site in St Neots, UK. The paper is sourced from trusted UK suppliers to ensure high quality and sustainability, while the paper honeycomb and board is manufactured in-house. This local production model supports the UK industry, reduces CO2 emissions, and aligns with Net Zero goals. Manufacturing in the UK ensures consistent quality, reliable supply chains, and faster lead times. Our approach provides environmental and logistical benefits and reduces the risks associated with global supply chain disruptions. Learn more about Dufaylite here.

Will honeycomb void fillers make the packing process longer?

Honeycomb void fillers integrate seamlessly into packing lines, so everything moves quickly and efficiently without the environmental drawbacks of polystyrene. For production managers, this design means faster packing times with fewer hands required, reducing labour costs and increasing output. With custom sizes and configurations tailored to specific needs, it’s easier to maintain smooth operations while achieving sustainability goals.

Ready to make the switch? Contact us today

Ready to transform your packaging with a smarter, sustainable solution? Get in touch with our team today to discuss your bespoke honeycomb void fill solution. Let’s work together to fill those gaps, protect your products, and achieve your sustainability goals.