One of the most significant trends in the packaging industry today is the search for effective alternatives to traditional loose fill materials. Loose fill has long been a popular choice due to its low cost, biodegradable options, and excellent ability to cushion products during transport by filling every nook and cranny. However, as businesses evolve and become more safety-conscious, many are looking for smarter, safer, and more efficient solutions.

While loose fill offers great protection, it can be messy, hard to store, and time-consuming to use compared to products like air cushions, paper, or bubble wrap. In some cases, companies may not have the resources to switch to fully automated systems, but that doesn’t mean they can’t make safer choices. Traditional polystyrene-based loose fill is flammable, and when stored in large quantities, it can pose a serious fire hazard in warehouses.

In this post, I’ll share what I suggested to Phil, who was concerned about the fire risks associated with his current loose fill solution.

Dear Doctor,

I need some advice. I currently use a lot of loose fill for packaging, but I'm worried about how safe it is to store in my warehouse. My space is limited, and if there were a fire, the loose fill could make things worse because it's so flammable. What can I do to reduce this risk?

Thanks, Phil

Hi Phil,

Thanks for reaching out. It’s always important to think beyond just cost and quantity when choosing packaging materials. Storage space, ease of use, and workplace safety should all be part of your decision-making process.

To help reduce the fire risk in your warehouse, I would recommend considering an alternative to polystyrene-based loose fill. Vermiculite loose fill chips are an excellent option. They are 100% natural, lightweight, and highly absorbent. You simply pour them around your products to fill gaps and provide protection.

What makes vermiculite stand out is that it’s completely fireproof and fiber-free. This means it’s not only safe to use in your warehouse but also suitable for packing hazardous goods. By switching to this material, you’ll significantly reduce the risk of fire spreading and create a safer working environment.

I hope this helps. Let me know if you'd like more information on other alternatives.

Best wishes,
The Packaging Doctor

Note: All the packaging problems our doctor receives are real queries from customers or non-customers.

If you have a packaging problem that needs diagnosing, get in touch on Twitter @kitepackaging or email us directly.

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