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What are air cushions?

Air cushions are a modern and efficient type of protective packaging material that uses air-filled pillows to fill empty spaces in boxes, ensuring optimal protection of goods during transport. Specifically, air cushion pillows are not only lightweight and cost-effective but also easily recyclable, which is highly important today. Additionally, they are available in various shapes and materials to perfectly meet specific customer needs.
 
Special machines are used for their production, which efficiently inflate air into bubble films or pillows. This process takes place directly at the packaging site, which is highly practical. Thanks to these properties, this type of cushioning is not only highly effective but also environmentally friendly, as it minimizes the need for storage space, significantly reducing transportation costs. In short, you only transport the film, not the air, which ultimately saves both space and money.

What are the types of air cushions?

Air cushions are divided into two main groups: single-chamber and multi-chamber. 

Single-chamber air cushions are primarily used to fill empty space in packages. They are typically produced with a width of 200 mm and lengths of 100, 130, or 200 mm. Individual cushions are separated by perforations for easy tearing to the length needed for a specific package. 

The main function of multi-chamber cushions is product protection. These cushions consist of smaller chambers connected in sections, similar to an ice cube bag. The standard width is 400 mm, with length and shape varying depending on the specific type. The most popular types by far are the 4-tube and 7-tube cushions.
Zdaleka nejpopulárnější jsou polštáře 4 tube a 7 tube.

Single-chamber

Vzduchový polštářek s logem firmy a informacemi o ekologii
  • Šíře: 200mm
  • Délka (perforace): 100, 130, 150, 200mm
  • Purpose: filling empty space

2 Tube

Vícekomorová matrace tvovřená dvěma válci v řadě
  • Width: 400mm
  • Lenght (perforation): 150mm
  • Cushion height: approx. 40mm
  • Purpose: filling empty space / product protection

4 Tube

Vícekomorová matrace tvořená čtyřmi válci v řadě
  • Width: 400mm
  • Lenght (perforation): 150mm
  • Cushion height: approx. 35mm
  • Purpose: filling empty space / product protection

7 Tube

Vícekomorová matrace tvořená většími bublinkami
  • Width: 400, 800mm
  • Lenght (perforation): 170mm
  • Cushion height: approx. 19mm
  • Purpose: product protection

7 Tube Square

Vícekomorová matrace tvořená čtvercovými bublinami
  • Width: 400, 800mm
  • Lenght (perforation): 190mm
  • Cushion height: approx. 23mm
  • Purpose: product protection

Duo

Vzduchový polštář DUO se dvěma velkými komorami
  • Width: 400, 800mm
  • Lenght (perforation): 150mm
  • Cushion height: approx. 100mm
  • Purpose: filling empty space
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What materials are used?

The main materials used for the production of air cushions are LDPE (Low-Density Polyethylene) and HDPE (High-Density Polyethylene). They differ in density, strength, temperature resistance, and transparency. LDPE is softer and more flexible than HDPE. It also has a lower melting point (115°C) and is more transparent. In contrast, HDPE is rigid and durable, offering greater chemical resistance. Its higher melting point (135°C) allows it to withstand higher temperatures than LDPE.
Previously, the rigidity of HDPE was a disadvantage when used as a material for air cushions. However, today HDPE can be manufactured to overcome this limitation. The result is a material that offers higher strength, temperature resistance, and sufficient flexibility to prevent bursting or deformation under pressure.

What are the ecological alternatives?

Air cushions are inherently eco-friendly for several reasons. Compared to crumpled paper, they require significantly less material to fill the same volume in a package. This property not only reduces the ecological footprint of air cushions several times over but also brings additional benefits. Specifically, fewer raw materials need to be extracted and processed, less material needs to be transported for use, and less waste is generated for recycling. For example, the weight of paper needed to package the same shipment is approximately 10 times higher! Additionally, end consumers can easily puncture the film, minimizing the volume of waste, which is again significantly smaller compared to crumpled paper.
 
At first glance, various bio-materials may seem like an interesting alternative. Currently, there are more than 400 different types of bio and biodegradable plastics, but this diversity is one of the main problems—chaos. The average consumer has almost no chance of navigating the multitude of different materials, technologies, and names. Moreover, distinguishing between these materials without costly tests and laboratory equipment is impossible, even for material experts. So, what is the average consumer’s perception of bioplastics? They often imagine a natural, decomposable material. However, this is a misconception. Bioplastics also include plastics from fossil sources, such as PBAT or PCL, or bioPE, bioPET, and bioPA, which, while derived from renewable sources, are not biodegradable.
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Air cushions made of paper without hidden plastics!

Our air cushions made from recycled paper are truly eco-friendly! They do not contain the commonly used inner plastic layer that prevents both recycling and composting.

The air barrier is formed by a layer of cornstarch.

This filling is the most efficient use of paper as a protective packaging material for your products.

Papírové polštáře s vnitřní vrstvou z kukuřičného škrobu
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What machines are used for preparing pillows?

Air fillings are supplied as standard in the form of film on a roll with a specific final shape and perforations for easy tearing off of individual pillows. This film is then inflated and prepared for use at the packaging site using a special compact machine. 
We currently offer two types of machines.

BP2000

BP2000 je základní stroj pro přípravu vzduchových výplní. Jak jednokomorvých polštářů tak vícekomorových matrací.
  • Purpose: smaller companies
  • Speed: up to 5m/min
  • Rolls lenght (200/400mm): 700/450m
  • Weight: 4kg
  • Dimensions (l,h,d): 305,400, 280mm

BP4000

BP4000 je stroj pro přípravu vzduchových výplní pro náročnější zákazníky. Jak jednokomorvých polštářů tak vícekomorových matrací.
  • Purpose: medium and bigger companies
  • Speed: up to 15m/min
  • Rolls lenght(200/400mm): 700, 1500, 2000/450m
  • Weight: 6kg
  • Dimensions (l,h,d): 315,300, 315mm
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What are the possibilities for machine integration?

Integrating the machine into the packaging workplace is becoming very important, especially for larger companies. Time savings combined with greater user comfort are another step toward automating the packaging process. The operator always has packaging material conveniently at hand.
The technical solution is always chosen based on the specific workplace.

Ducting

Rameno zvedne stroj nad koš pro tiché doplnění koše vzduchovými polštáři
  • The machine is electrically extended to the working position.
  • Convenient solution > just press a button
  • Silent solution

Potrubí

Potrubí žene vzduchové polštáře do koše nad balícím pracovištěm
  • Filling delivered to the bin via air duct.
  • Automated start
  • Transport of pillows over longer distances
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