How to choose the right air cushion film for your shipments?

Choosing the right air cushion film is a key factor that affects both shipment safety and your overall packaging and delivery costs. If the selected air cushion film isn’t suitable, a number of problems may arise: excessive use of packaging material, higher packing costs, and increased risk of product damage during transportation.

By selecting the right film type, you can optimize the entire packing process — reduce costs, speed up order preparation, and ensure better protection for your products until they reach the customer.

The two most popular air packaging types — Air pillows and Air protective film

In e-commerce, the most commonly used air packaging options are air pillows and air protective film. Both can be used individually or combined, allowing you to adapt your packing method to different shipment types and products.

Air pillows are small, air-filled bags used to fill voids inside boxes. They don’t wrap the product itself but hold it securely in place during transportation, preventing it from moving or bumping against the box walls. This solution is ideal for products that are already packed in their own packaging, such as boxes or blisters. Pillows are also extremely handy when combining several products of different sizes in one larger box — they keep everything stable and protected.

Air protective film works similarly to traditional bubble wrap. The product is tightly wrapped with the film, creating a protective layer that shields it from shocks and mechanical damage. This solution is perfect for fragile or valuable items that need extra protection — for example, dishes, bottles, electronics, and more.

Many companies choose to combine both packaging types: the product is first wrapped with protective film, and the empty spaces in the box are filled with air pillows. This approach provides flexibility — you can use boxes of various sizes (including reused ones) while ensuring a secure and stable packaging solution.

Comparing air cushion film materials: HDPE vs PA (PA/PE)

Air cushion films are made from different materials, and the choice directly impacts the level of protection, cost, and recyclability. The most common materials are HDPE and PA/PE.

HDPE (High-Density Polyethylene) is lightweight, fully recyclable, and relatively inexpensive. It’s ideal for shorter shipping times when products reach customers within a few days. HDPE air protective film maintains its protective properties for approximately 11–14 days, while air pillows last up to 18 days. Using machines with double sealing, such as the Pakful D80, this time can be extended by another 2–3 days. This is why HDPE is the most popular choice for local and regional shipments with fast turnover.

PA/PE (multi-layer film with a nylon layer) provides significantly longer air retention — from several months to even years. Although it’s harder to recycle, this material offers outstanding long-term protection. PA film is crystal-clear and high-quality, making it ideal for long-distance shipments, export, or situations where goods are stored in the warehouse for extended periods before delivery. It’s often chosen by companies shipping fragile or valuable products to other markets where delivery can take weeks or even months.

Film thickness and suitability for different shipment types

In addition to material, film thickness plays an important role, as it affects both the level of protection and material consumption/cost.

Pakful offers optimized film thicknesses that strike the right balance between cost and protection:

◼️ HDPE films most commonly use 20 microns, suitable for most standard e-commerce shipments. Depending on the need, HDPE thickness can vary between 15 and 30 microns.
◼️ PA films are typically 25 microns thick but are also available in much thicker versions — up to 70 microns for extra protection. PA film not only retains air longer but is also more resistant to punctures and tears, making it ideal for products with sharp edges or corners, such as metal parts, tools, or rigid boxes.

Film thickness and material should be adapted to the product type and shipment specifics:

◼️ Small, pre-packed products — thinner HDPE film or air pillows for void filling.
◼️ Heavy or sharp items — thicker PA protective film for stronger protection.
◼️ Large shipments — often a combination of different film types to achieve maximum protection.

Choosing sustainable materials

Air packaging is inherently more sustainable than many traditional packing materials such as bubble wrap or paper fillers. Because the film is only inflated at the moment of packing, it requires minimal storage space, which reduces transportation volumes and the overall carbon footprint in warehousing and logistics.

Air pillows and protective films offer effective protection using minimal material. This is especially true for HDPE films, which are 100% recyclable and can be easily disposed of with other plastic waste. When properly sorted, HDPE can be recycled multiple times, reducing waste and minimizing the environmental impact of your packaging. For companies looking to cut costs and act responsibly, HDPE air packaging is an excellent choice.

Conclusion

Selecting the right air cushion film helps reduce costs, improve shipment safety, and make your packing process more efficient.

HDPE films are a great solution for local shipments — recyclable, cost-effective, and easy to use in daily operations. PA/PE films offer long-term protection and high durability, which is essential for exports, fragile, or high-value goods. By adjusting both material and thickness to the specific shipment type, you can ensure optimal protection while minimizing unnecessary packaging use.

Not sure which film is best for your shipments?

Get in touch with us for a free consultation — our specialists will help you choose the most suitable solution for your business.

Email: veikals@pakful.lv
Phone: +371 26660018