Loose Fill

Features & Benefits

• Loose Fill / Flo-Pak consists of lightweight green pieces made with recycled content
• Available in 2 cu ft and 15 cu ft bag volumes
• 2 cu ft equals approximately 56.6 litres or 0.057 cubic metres
• 15 cu ft equals approximately 424.8 litres or 0.425 cubic metres
• The 15 cu ft option uses 100% recycled green chips
• Sold per bag, so customers can select the volume that suits their packing requirements
• Helps fill empty spaces around suitable products inside cartons
• Interlocking pieces settle around different shapes and help limit movement
• Adds lightweight cushioning without significantly increasing parcel weight
• Suitable for irregular, delicate and mixed-shape products when used as part of an appropriate packing system
• Quick to pour around products during repetitive packing tasks
• Useful for e-commerce, retail, warehousing, fulfilment, manufacturing, removals and storage
• Can be retained and reused when the pieces remain clean, dry and undamaged
• Available for delivery to UK mainland addresses

Common Uses

These green packing pieces suit many general packing and dispatch tasks, including:

• Filling suitable empty spaces in cardboard boxes
• Cushioning irregularly shaped products
• Reducing movement around boxed items
• Supporting ceramics and ornaments with additional protection
• Packing glassware inside a suitable complete packaging system
• Protecting retail and e-commerce orders
• Separating mixed products within larger cartons
• Packing spare parts, components and accessories
• Supporting promotional products and giftware
• Preparing office equipment for storage or transport
• Packing house-moving and archive boxes
• Filling presentation boxes and hampers around separately wrapped contents
• Supporting products inside export cartons where the completed pack meets all relevant requirements

However, always consider the product’s size, weight, shape, surface finish, fragility and value before selecting a protective-packaging system. Test the completed pack when damage prevention is critical.

Loose Fill / Flo-Pak

Our Loose Fill / Flo-Pak provides a simple way to occupy surplus space inside shipping cartons. The green pieces flow around suitable products and reach gaps that can be difficult to fill with flat protective materials. Packers can create support around curved, detailed and irregular shapes.

The lightweight pieces interlock and settle as the carton fills. As a result, they help restrict unwanted movement during ordinary handling and transport. However, the pieces do not replace a correctly sized carton, suitable product wrapping or specialist protection for highly fragile goods.

Both bag sizes contain green pieces made with recycled content. Additionally, the 15 cu ft product listing specifies 100% recycled green chips. Businesses can choose a recycled-content void-fill solution and select a bag volume that matches their storage space and packing frequency.

Customers can use the smaller bag for occasional packing or compact work areas. Meanwhile, the larger bag supports regular dispatch operations and higher-volume packing stations. Use only enough material to hold the item securely without placing excessive pressure on it.

Loose Fill / Flo-Pak Sizes and Specifications

The range combines the following bag volumes:

• 2 cu ft: approximately 56.6 litres or 0.057 cubic metres
• 15 cu ft: approximately 424.8 litres or 0.425 cubic metres

The main product specifications are:

• Product type: loose void-fill packaging
• Alternative names: Flo-Pak, packing peanuts, packing chips and loose-fill pieces
• Colour: green
• Material characteristic: made with recycled content
• 15 cu ft recycled content: 100% recycled green chips
• Sales unit: sold per bag
• Available volumes: 2 cu ft and 15 cu ft
• Food-contact suitability: not confirmed
• Anti-static performance: not confirmed
• Biodegradability: not confirmed

Although the listed quantities describe nominal bag volumes, the pieces can settle during storage and transit. Therefore, the bag shape and apparent fill level may vary without changing the intended sales volume. Customers with a critical usage calculation should allow for the carton shape, product displacement and preferred packing density.

Understanding Loose Fill / Flo-Pak Volume

The product volumes use cubic feet rather than linear dimensions. The 2 cu ft size describes approximately 56.6 litres of volume, and the 15 cu ft size describes approximately 424.8 litres. In metric terms, these figures equal approximately 0.057 cubic metres and 0.425 cubic metres respectively.

However, a bag’s stated volume does not translate directly into a fixed number of parcels. Each carton requires a different amount because products occupy different proportions of the internal space. Irregular items may create more gaps than neatly shaped products of a similar overall size.

To estimate your requirement, first calculate or measure the usable internal carton volume. Next, subtract the approximate volume occupied by the product and any other protective materials. Finally, allow extra material for settling and for the level of support the complete pack requires.

A short packing trial offers the most reliable guide for repeat orders. Consequently, businesses can compare actual usage per carton before choosing between the two available volumes.

Choosing Loose Fill / Flo-Pak

Choose Loose Fill / Flo-Pak according to your packing frequency, available storage space and typical void-fill usage. The 2 cu ft bag offers a practical choice for occasional dispatches, smaller operations or situations where storage space remains limited.

By contrast, the 15 cu ft bag provides considerably more material for regular carton filling and busier work areas. Therefore, it can reduce the frequency of replenishment at a high-use packing station. Businesses should confirm that they have enough clean, dry indoor space to store the larger bag safely.

Product characteristics matter. For example, heavy, sharply pointed, highly fragile or high-value goods may require edge protectors, wrapping, foam, corrugated inserts or another engineered packaging solution in addition to loose fill. A close-fitting outer carton generally needs less void fill and can create a more controlled completed pack.

How to Use Loose Fill / Flo-Pak

First, select a strong outer carton that suits the item’s dimensions, weight and expected handling conditions. Next, assemble and seal the base securely with suitable packing tape. Then, add an even base layer of green pieces before positioning the product.

For suitable items, follow these steps:

1. Inspect the product and identify delicate faces, sharp edges and projecting parts.
2. Wrap or protect vulnerable areas separately where necessary.
3. Pour a base layer into the carton.
4. Place the item centrally and maintain suitable clearance from every carton wall.
5. Add more pieces around the sides and into accessible gaps.
6. Gently settle the contents without crushing the product.
7. Fill the remaining upper space so the item cannot move excessively.
8. Close the carton and check that the flaps sit naturally without bulging.
9. Seal the carton securely and apply any required labels.
10. Test the completed package under conditions appropriate to the intended journey.

Finally, open a trial carton after the test and inspect both the product and the packing arrangement. If the item has moved, adjust the carton size, wrapping method or quantity of void fill before continuing with a larger packing run.

Cushioning with Loose Fill / Flo-Pak

The green pieces create multiple contact points around suitable products. Consequently, Loose Fill / Flo-Pak can help absorb minor knocks and limit movement within the carton during routine handling. Its low weight also makes it useful when packers need volume without adding a dense cushioning material.

Because the pieces flow freely, they can surround shapes that do not sit evenly against flat pads or sheets. They can fill small gaps between separately protected products when the packing design allows multiple items in one carton.

However, loose pieces can shift or settle as a parcel moves. Therefore, packers should fill the space consistently and check that the product remains supported on every side. An underfilled carton may allow movement, while an overfilled carton may place unwanted pressure on the contents or prevent the flaps from closing correctly.

For fragile goods, combine the material with suitable primary cushioning and a strong outer box. Additionally, use dividers where products could collide, and protect sharp edges that might damage the carton or neighbouring items.

Loose Fill / Flo-Pak for Business, Storage and Removals

Loose Fill / Flo-Pak supports businesses that pack varied product shapes and order sizes. For example, online retailers can use it to fill surplus carton space around separately wrapped goods, and manufacturers can use it around suitable components and spare parts.

Fulfilment teams may value the straightforward pour-and-fill method. Packers can adapt the amount quickly when several carton formats pass through the same workstation. Retailers and gift suppliers can use the green pieces around protected presentation items where the colour and loose-fill appearance suit the desired presentation.

During removals or storage, the pieces can support suitable ornaments, accessories and household items inside strong cartons. However, use separate surface protection where objects have delicate finishes, and never rely on loose fill alone for valuable or easily damaged belongings.

Because both volumes are sold per bag, customers can select the smaller or larger option without committing to a fixed carton quantity. Express Packaging can deliver the product to UK mainland addresses.

Storing Loose Fill / Flo-Pak

Store Loose Fill / Flo-Pak indoors in a clean, dry and well-ventilated area. In addition, keep the bag closed when it is not in use so dust, dirt and moisture cannot contaminate the pieces.

Keep the product away from:

• Naked flames and ignition sources
• Hot surfaces and excessive temperatures
• Direct sunlight
• Rain, condensation and damp areas
• Oils, solvents and aggressive chemicals
• Dust and workshop debris
• Sharp tools that could puncture the outer bag
• Rodents and other pests

Because the pieces are lightweight, draughts can scatter them around a packing area. Therefore, pour them carefully and keep the storage bag controlled while dispensing. Clean up spills promptly to prevent pieces from creating a slip or housekeeping hazard.

Do not stack unstable or heavy stock on the bag. Pressure can compress the contents and may damage the outer packaging. Rotate stock so older bags enter use first.

Alternative Names for Loose Fill / Flo-Pak

Customers may also refer to this product as:

• Packing peanuts
• Packing chips
• Green packing pieces
• Recycled-content loose fill
• Parcel void fill
• Carton void fill
• Protective loose fill
• Lightweight box filler
• Packaging peanuts
• Loose cushioning pieces
• Green void-fill chips
• Eco-fill packing pieces

Although these terms often describe similar products, material composition, recycled-content percentage, colour and performance can differ. Therefore, check the stated green colour, recycled-content construction and selected bag volume when comparing alternatives. In particular, note that the listing specifically identifies the 15 cu ft option as using 100% recycled green chips.

Food Safety Information

Direct food-contact suitability has not been confirmed for these products. Therefore, do not place unpackaged food in direct contact with the green pieces.

When protecting packaged food, keep it completely enclosed within suitable food-contact packaging. Additionally, make sure the loose pieces cannot enter, puncture or contaminate the primary pack.

Businesses operating in regulated food environments should complete their own risk assessment and request current compliance documents before use. They should consider whether loose particles suit the hygiene controls in their packing area.

PPWR Compliance Information

The EU Packaging and Packaging Waste Regulation, Regulation (EU) 2025/40, introduces requirements for packaging placed on the EU market.

However, compliance depends on the complete packaging system, supply chain, intended market and applicable implementation dates. Therefore, this description should not be treated as a declaration of PPWR compliance for either bag size.

Both products use recycled-content green pieces, and the 15 cu ft listing specifies 100% recycled green chips. Nevertheless, recycled content alone does not confirm that a finished package meets every applicable requirement.

Consequently, businesses should request current technical evidence before making regulatory or environmental claims. They should also assess the complete packaging configuration against the rules that apply to their organisation and target market.

Sample Requests

Small samples may be available to help customers assess the green colour, piece shape and suitability for their products.

To request a sample, email sales@expresspackaging.co.uk or call 0121 622 2347.

When contacting us, provide details of the intended item, carton size, application and expected order quantity. Therefore, our team can identify the relevant product and help arrange an appropriate test.

Customers can also use the same contact details to discuss volume requirements, stock availability and delivery to UK mainland addresses.

Illustration Only

Product images are for general illustration only. Consequently, the exact green shade, piece shape, bag appearance and finishing details may vary between manufacturing batches.

The stated quantities describe nominal bag volumes, and the lightweight pieces may settle during storage and transport. The apparent fill level and bag dimensions can vary.

Request a sample before committing to an application where appearance, packing performance or compatibility is critical. Customers should test the complete packaging system under realistic handling, storage and transport conditions.