Filling the void: HexcelPack unveils plastic-replacement box cushioning solution HexaFil

17 Aug 2022 --- HexcelPack is introducing HexaFil, a 100% paper-based void fill solution that provides improved block and bracing along with additional cushioning in packaging boxes compared to traditional paper and plastic-based void fill options like bubble wrap. 

HexaFil utilizes the same three-dimensional hexagon design and proprietary slit paper technology as its signature cushioning product, HexcelWrap. This method makes the paper “flex,” expanding its volume while maximizing the strength and stiffness of its fibers. When HexaFil is dispensed either automatically or manually, it spirals like a helix. 

This creates the bulk required for effective void fill, ensuring packed items will be nestled in a stable position and, therefore, less likely to shift during transport. It also results in a superior void fill product that outperforms environmentally-harmful alternatives and reduces the number of materials required to ship consumers their products.

“Our HexaFil void fill is an ideal solution to boost packing efficiencies across e-commerce applications and perfectly aligns with our continued commitment to delivering innovative protective packaging solutions that are both cost-effective and sustainable,” remarks Lorne Herszkowicz, partner at HexcelPack.

“Furthermore, when most of our retail customers are experiencing extremely high shipping volumes and an increased demand for eco-friendly packaging products, we are thrilled to bring AutoHexaFil to market as our first of many innovations in automated packaging.”

HexaFil spirals to fill boxes efficiently and protect products. Automatic dispensing 
AutoHexaFil is the fully automatic dispensing solution designed specifically for the company’s HexaFil void fill. The machine uses a novel bladeless cutting technique to dispense the void fill material into corrugated shippers up to three times faster than alternatives. 

Fully automatic with a programmable screen and electric operation via foot pedal, the machine quickly dispenses HexaFil in preset lengths with no cutting blades or dangerous components needed. The AutoHexaFil stands at 1.98 meters tall and is adjustable to fit over packaging conveyor systems. The unit also has wheels for easy maneuvering. 

When speed is less of a factor, or in applications with lower shipping volume and space and technician constraints, like most ship-from-store operations, the company says Manual HexaFil is the better solution. The manual dispenser can be conveniently set next to a small packing table with the HexaFil easily dispensed from the roll by hand.

Both systems, however, are designed to be easy to integrate and use without the need for cutting mechanisms. The AutoHexaFil unit stops quickly and acts as a brake to easily pull the material apart in the same motion as tamping and closing the box. Both the manual and AutoHexaFil can be custom designed for each application with either table or floor mounting possible. 

HexaFil’s strengths 
HexcelPack says its new release is beneficial in three central areas: 

• Unsurpassed Product Protection: The Ultra Stretch technology gives HexaFil superior block and bracing, cushioning and product protection needed for shipping fragile items and reduces product damage. The interlocking material also ensures limited movement during transport. When combined with HexcelWrap, it provides an anti-migration and fully cushioned package.
• Environmental sustainability: Completely paper-based, HexaFil is made of 100% Program for the Endorsement of Forest Certification (PEFC) Canadian paper. Unlike single-use plastic bubbles, the paper used to produce HexaFil is curbside recyclable and biodegradable.
• Cost savings: AutoHexaFil is as impactful on the bottom line as it is the environment, claims the company. Retailers can increase shipping efficiencies and reduce labor costs by upgrading to an automated void fill machine versus a manual station. In most instances, the operation can reduce the amount of void fill used.

HexcelPack’s bubble wrap replacement
Hexafil is the latest in HexcelPack’s releases for the packaging industry, which aim to replace traditional materials with more cost-effective, environmentally sustainable solutions. 

Last year, the company released HexcelWrap, a protective paper-based wrapping system for product shipping as an alternative to bubble wrap and other plastic or foam-based materials. Three leading US retailers immediately began using the HexcelWrap system. 

The solution uses cushioning paper, product protection and packaging simplicity for e-commerce, retail catalogs, pharmaceutical and nutraceutical products, and third-party logistics and contract packaging applications.

By Louis Gore-Langton