Air cushion system: when does automation pay off in shipping?
· by Editorial team
An air cushion system is particularly worthwhile if you regularly pack shipments with changing voids and storage space for cushioning material is tight. The machine fills flat film with air only at the packing station. Whether it pays off depends on your volume, your products and suitable box sizes.
How does an air cushion machine work?
An air cushion system for void fill consists of two parts: a machine at the packing station and film that lies flat on the roll. Instead of ready-made cushions, you only store this roll. The machine fills the film with air as soon as you need cushions.
Depending on the system, different cushion shapes are produced. The Fill Air Rocket System is compactly built and produces up to 30 metres of air cushions per minute, for example to fill voids in the shipping box. The NewAir I.B. Flex creates large-volume air cushion mats directly at the packing station. Which shape suits you depends on whether you mainly fill voids or cushion products.
Is an air cushion machine worthwhile for your shipping?
It is not possible to state a fixed number of parcels at which a machine pays off in any credible way. Products, boxes and processes differ too much for that. These questions are more meaningful:
- Do you pack daily? A machine that only runs on a few days spreads its costs across a small number of parcels.
- Do your voids vary? Items of different sizes need void fill in varying quantities. On-demand cushions follow this need.
- Is storage space tight? Film on the roll only gains its volume at the packing station, whereas ready-made cushioning material already takes up space in storage.
- Do you cushion by hand today? Then check how much time cutting, crumpling and refilling cost at each packing station.
- What must the cushion achieve? If your products have a complex shape or need to be held in place, foam cushions or suspension packaging may also be an option. Suspension packaging holds sensitive products without letting them slip.
For very small or strongly fluctuating demand, a solution without a machine can be more sensible, for example foam cushion bags that you activate without a device.
What does an air cushion machine cost?
There is no flat-rate price that is right for every operation. The costs depend on the model, film and shipping volume. Consider the items separately for this reason:
- Machine: Model, performance and features determine the price.
- Film: This is the ongoing item, its consumption rises with the number of parcels.
- Power and footprint: The machine needs a fixed location and a power connection.
- Introduction: Your team gets to know the system, processes at the packing station change.
Against this stand costs you already bear today: storage space for ready-made cushioning material, working time for cushioning by hand and the consequences of damaged shipments. Only a calculation with your own figures will show how much these items change. Blanket savings promises are no substitute for it.
How does an air cushion system fit into logistics automation?
Automation in logistics does not have to start with conveyor technology. An obvious approach is the manual steps that repeat with every parcel. Cushioning is one of them.
For an air cushion machine to ease the daily workload, clarify three points in advance:
- Position: The cushions should be within reach, without additional walking distances.
- Film supply: Define who changes rolls and where the supply is stored.
- Boxes: Cushions complement suitable boxes, they do not replace them.
In our industry solutions, for example for online retail, we therefore consider product protection and the process at the packing station together.
Related to this article: Fill Air Rocket | Schnelles Luftkissen-System Bis zu 30 Meter Luftkissen pro Minute. Das Fill Air Rocket System ist kompakt, schnell und perfekt für den modernen E-Commerce. Hier informieren! More about Fill Air Rocket | Schnelles Luftkissen-System →
What does the PPWR mean for your air cushion system?
A machine does nothing to change the size of your box. That is precisely what will matter in future. According to a legal analysis by the IT-Recht Kanzlei, Art. 24 of the EU Packaging and Packaging Waste Regulation (PPWR) sets a maximum empty space (void) proportion of 50 % for e-commerce packaging as well as for transport and grouped packaging. The limit applies from 1 January 2030 or three years after the implementing act on the calculation method enters into force, whichever date is later. The EU Commission is to define this method by 12 February 2028.
Air cushions, paper and other void fill still count as empty space (void) here. More cushioning therefore does not make an oversized box compliant. For this reason, plan an air cushion system together with suitable made-to-measure shipping boxes: the box limits the empty space (void), the cushions secure the contents. As the calculation method is still pending, have your specific situation reviewed legally if in doubt.
Frequently asked questions
How much space does an air cushion system need?
The machine stands directly at the packing station, the Fill Air Rocket System, for example, is compactly built. For the supply, you store film rolls instead of ready-made cushions, because the film is only filled when needed. How much space you need depends on your consumption.
Do air cushions make an oversized box compliant?
No. According to the analysis by the IT-Recht Kanzlei, air cushions count as empty space (void) under the PPWR. For the future limit of no more than 50 %, the right box size is what matters.
What applies under the VerpackDG for shipping packaging?
Since 12 August 2026, the Packaging Law Implementation Act (Verpackungsrecht-Durchführungsgesetz, VerpackDG) has applied instead of the previous German Packaging Act (VerpackG). Shipping packaging to private end consumers remains subject to system participation. Manufacturers of such packaging register free of charge with the Central Agency Packaging Register (Zentrale Stelle Verpackungsregister) before first making it available and state the material type and mass for system participation. If you switch your void fill, check these details. It is best to clarify your obligations in individual cases legally.
Which air cushion system suits your shipping?
That depends on your products, boxes and processes. Alongside air cushions, paper cushioning systems are also an option. Let us know briefly via contact with the packaging specialist what conditions apply at your operation. We will be glad to help you and check with you which system suits your shipping.
Transparency note: This article was created with AI assistance and reviewed by our editorial team. The article image is AI-generated.