Void filler is the unglamorous part of a pack that decides whether the product arrives straight. Empty space in a carton or container lets the load move, and movement is what breaks corners, scratches faces and loosens strapping. Honeycomb blocks fill that space at a fraction of the weight of timber, and they can be cut to the exact gap rather than packed out with loose material.
Fill the gap, not the box
The instinct is to fill the carton with loose paper until it feels tight. That works for a parcel and fails for a pallet, because loose material settles and the load moves again by the time the container is opened.
A cut honeycomb block holds the gap open. Because the board is stiff, the block keeps its dimension and keeps the product pressed against the carton wall, which is where the load path should be.
Specification at a glance
Blocks are usually 20-30 mm board, laminated in layers to reach the required depth, with a small cell so the block face stays flat under compression.
| Gap | Build | Cell | Note |
|---|
| Up to 30 mm | One board | 4-6 mm | Cut to the gap |
| 50-100 mm | Laminated layers | 4 mm | Cells aligned along the gap |
| 100-200 mm | Laminated, edge banded | 4 mm | Band the edges to stop delamination |
| Wide shallow gap | One thick board | 6 mm | Large footprint, low pressure |
| Corner void | Die-cut L block | 4 mm | Fits the corner, not the wall |
Building a block to a depth
A single board gives one thickness. For a 100 mm gap, layers of board are bonded together with the cells running in the same direction, so the block resists compression along the gap. Bonding with the cells crossed makes a block that resists sideways crush but compresses more along the gap, which is usually the wrong choice here.
Keep the block footprint large. A small block concentrates load on a small area of the product; a wider, thinner block distributes it. Where the gap is deep and narrow, two blocks at the ends beat one in the middle.
Where blocking replaces bracing
In a container, blocking and bracing stops a load shifting along the deck. Honeycomb blocks are used against the product frame rather than against the container wall, because the wall is not designed to take a point load from inside.
In a carton, the same block is used to hold a product away from the wall so a corner impact is absorbed by air and board rather than by the product.
Questions buyers ask before ordering
Can blocks be laminated to a specific depth?
Yes. Layers are bonded to the depth you need, with the cell direction set to resist compression along the gap.
Is a honeycomb block as strong as timber dunnage?
No, and it should not be sold as such. It blocks movement and spreads load; a structural brace still needs timber or steel.
How do I stop the block delaminating?
Band or tape the edges, and keep the block dry. Delamination almost always starts at a wet or crushed edge.
Can void fillers be die-cut to a shape?
Yes, including L shapes and profiles that follow a product corner.
What is the lightest option for air freight?
A single 10-15 mm board with a 6-8 mm cell, cut to the gap, is the lightest way to stop movement.
Send the sheet size, thickness, core cell and facing weight to mona@hengnicepacking.com and we will quote the construction that fits the load.
