Sustainable Packaging Blog

What is HexaFil™?

Written by David Goodrich | Sep 11, 2025 4:30:00 PM

Regardless of the size of your business, you’ve probably come across HexaFil™ when shopping for packing materials. If you’re not sure exactly what it is, this blog is for you.

HexaFil™ is a sustainable void filler from HexcelPack. It’s designed to protect and cushion merchandise during shipping. Keep reading to learn more about:

  • The function of void fill is to reduce damage and decrease returns
  • What to look for when buying void fill for your company
  • How sustainable void fill compares to old-fashioned plastic void fill

Our goal is to help you understand how HexaFil™ can streamline your packing process, boost customer satisfaction, and improve your bottom line.

What Is the Purpose of Void Fill?

Void fill is a type of packing material that fits into voids (empty spaces) in boxes. Typically, it’s used around merchandise in cardboard shipping boxes. But it can also be used to protect merchandise in interior containers, like subscription boxes.

The void filler reduces the risk of damage from impact and shifting in transit. If you think about how much the average parcel is jostled on its way to a customer, that makes sense.

Without void fill, your items can get broken or worn in transit. This costs your business in returns and exchanges. But it also cuts into revenue if an unhappy customer leaves a negative review.

These days, customers are reviewing products everywhere, including in social media unboxing videos. Void fill, like HexaFil™, helps give your merchandise a beautiful presentation. And it prevents items from rubbing against each other, keeping them pristine at first viewing.

Void fill is commonly found in e-commerce shipments. But it’s also used in other industries, such as:

  • Electronics
  • Optics
  • Medical devices
  • Pharmaceuticals
  • Aerospace
  • Automotive
  • Fine arts

Fragile and valuable items need dependable cushioning, whether they’re being shipped to customers or sent internally between your company's branches.

Is HexaFil™ Right for Your Business?

You may be wondering if HexaFil™ is the right packing material for your business. Below are four scenarios where this sustainable void fill would be an ideal solution.

Your Return Rate for Damage Is Too High

Some industries naturally have to worry about breakage. If you sell ceramics, glassware, and beauty products, for example, you know about this concern.

It’s recommended that even small businesses track their return rate and monitor customer complaints about damaged items. The cost of a poor return rate is multifold:

  • Shipping expenses for returns and exchanges
  • The cost of labor to handle returns and exchanges
  • Eating the cost of damaged and unusable goods
  • Losing new customers due to poor online reviews

Solution: Use a void fill like HexaFil™ that doesn’t flatten out during transit. Its innovative honeycomb design uses slit-paper construction to provide 3D protection until your merchandise reaches its destination.

You Need More Packing Consistency

Inconsistent packaging processes can happen for several reasons. One common one is having packing take place in different locations. Maybe you have employees packing your fragile items at different store locations. Or you might have packing stations at both the checkout counter and in the back for online orders.

Another reason for inconsistency is hiring temporary or seasonal help to assist with busy periods. As with multiple locations, you have many people using varying levels of packing protection. Too little and you get a lot of breakage; too much and you’re wasting packing supplies.

Solution: HexaFil™ offers manual or automated dispensing—or a combination of both. HexaFil™ Fill in a Box™ is perfect for packing on the go, like at art fairs or pop-up shops. AutoHexaFil™ uses machine dispensing to enable efficient, high-volume packing. Set the dispenser's speed and volume, and you get the same amount of void fill every time. It’s great when you want to make sure your mail orders are getting adequate cushioning without waste.

Your Products Are Featured in Influencer Posts

As mentioned above, you want to ensure your merchandise makes the best possible impression from the moment of unboxing. You can’t have influencers on Instagram or YouTube removing broken, scratched, or leaking products from their box.

In addition, you want your products to look super attractive on camera. Today’s online reviews are competitive. You want a presentation that goes above and beyond to woo new customers.

Solution: You already know that HexaFil™ provides outstanding protection for your merchandise. But it also makes it look fantastic. It’s available in both natural and white shades to enhance your products in every unboxing.

You Want to Comply with Shipping Regulations and Meet Customer Demands

There is a growing consumer movement towards sustainable packaging, especially among younger demographics. They’re throwing their support behind companies that use eco-friendly packing materials. And they’re willing to pay more for sustainability.

State governments and countries around the world are following suit. New regulations have been passed or are being proposed to phase out single-use packaging, particularly plastic packaging. In a few years, any business that ships to these states, as well as to the European Union or many countries in Asia and Oceania, will be required to use sustainable packaging.

Solution: HexaFil™ is sustainable, along with HexcelPack’s other packing solutions:

By using these packing materials, you appeal to environmentally conscious customers. And you stay compliant amid ever-changing packaging rules.

Why Is Sustainable Void Fill the Best Option Today?

What exactly makes the HexcelPak suite of packaging solutions sustainable?

  • They are made from renewable resources with a lower impact on the planet
  • They are compostable and/or curbside recyclable, unlike most plastics
  • They do not contain materials that break down into harmful microplastics

Microplastics are unfortunately everywhere around the globe today—in our oceans, rain, and snow. They are linked to a long list of health problems in humans, including cardiovascular disease.

A large proportion of microplastics in the environment comes from nonrecyclable plastic waste, including packaging. So it makes sense to try to reduce this burden by using sustainable packaging.

Instead of using packaging once and having your customers throw it away, you can help create a circular economy. That means the packaging you use is recycled into other items, so the cycle continues, rather than ending in a landfill.

See for Yourself How Well HexaFil™ Performs

Ready to test out the superior cushioning and efficiency of HexaFil™? Send us your items for repacking, and we’ll send them back to you. It’s the best way to see firsthand how well our HexcelPack void fill performs.

Or you can purchase HexaFil™ to use right away. Small operations, like Etsy stores and eBay sellers, may find what they need in our online store. For larger quantities, reach out to our team today. We’re happy to help you with dispensing options and other sustainable packaging solutions for your business, too.