Shipping Too Much Air? PPWR’s 50% Empty-Space Cap Is Coming.
PPWR entered into force in early 2025, and one of its headline requirements is aimed directly at e-commerce, transport, and grouped packaging: empty space ratio must not exceed 50%. While the obligation fully applies from 2030, the direction is clear — brands shipping into the EU are expected to start redesigning now, not later. In simple terms, the empty space ratio compares the volume of your packaging to the volume of the actual product inside. Void fill, oversized boxes, layers of bubble wrap — they all count as empty space. If your package is more than half air, it won’t meet the new rules. You need cushioning that does three things at once: Conforms tightly to the product, so protection doesn’t force you into a bigger box. Adds almost no material weight or volume of its own — remember, Article 10 of the PPWR separately requires packaging weight and volume to be minimised to what’s functionally necessary. Works fast on the packing line, because compliance that costs you throughput won’t survive contact with peak season. That’s exactly where air column bag — commonly known as air pillows, air columns, or air cushion bags — comes in. How air column bags help you get ahead of PPWR Air column bag isn’t just another type of void fill. When used correctly, it changes the way you think about box sizing and product protection. Here’s what makes it different. Custom-fit protection means smaller boxes Air column bags are inflated to wrap tightly around the product, holding it securely in place. Because the cushioning follows the product’s shape, you can often switch to a smaller outer box without increasing damage risk. Smaller box + snug cushioning = less empty space. That’s the simplest way to reduce your empty space ratio without compromising safety. They’re weightless…
