Sealed Air introduces compact paper-based cushioning system

Automation meets sustainability in protective packaging

Sealed Air has launched a compact paper-based cushioning system designed to expand access to fibre-based protective packaging, particularly for space-constrained packing environments.

The new system enables businesses to produce protective paper pads on demand, offering an alternative to traditional plastic-based cushioning materials such as bubble wrap and foam. By generating cushioning directly at the point of packing, the equipment supports more streamlined workflows while reducing dependency on pre-manufactured packaging materials.

A key feature of the system is its compact footprint, making it suitable for smaller operations, including e-commerce fulfilment centres, retail backrooms and decentralised packing stations. As fulfilment models continue to evolve, demand is increasing for solutions that can deliver both efficiency and flexibility within limited space.

The machine integrates directly into packing lines, allowing operators to create the required amount of cushioning material in real time. This helps to reduce material waste, improve packing speed and minimise storage requirements. In addition, the use of paper-based materials supports easier disposal and recycling, aligning with the wider industry shift towards mono-material packaging systems.

The launch reflects a broader trend within packaging machinery, where sustainability is increasingly being addressed through equipment innovation rather than materials alone. By enabling the use of fibre-based alternatives without compromising operational efficiency, systems like this are helping businesses transition away from plastics in a practical, scalable way.

At the same time, regulatory pressure and consumer expectations are accelerating this shift. Brands and retailers are under growing scrutiny to reduce plastic usage and improve recyclability across their packaging formats. For many, the challenge lies not only in selecting alternative materials, but in adapting processes and infrastructure to support them.

Paper-based cushioning systems represent one of the more accessible routes to change. They allow businesses to make tangible improvements without requiring a complete overhaul of existing operations. As a result, compact, flexible machinery solutions are becoming increasingly important in bridging the gap between sustainability ambition and operational reality.

Looking ahead, demand for integrated, on-demand packaging systems is expected to grow, particularly in fast-moving sectors such as e-commerce. Equipment that combines efficiency, adaptability and sustainability will play a central role in shaping how protective packaging evolves over the coming years.