It is important to cushion the contents of your package properly.

Ensure that you wrap each item separately. Fragile articles need separation from each other, and from the corners, sides, top, and bottom of the box.

Each item should be surrounded by at least two inches (5.08 cm) of cushioning and be placed at least two inches (5.08 cm) away from the walls of the box. This prevents product-against-product damage and protects contents from shock and vibration, which can pass from the outside of the box to the contents.

Proper cushioning material, combined with a strong outer container will fully protect your shipment. Use enough cushioning material to ensure that the contents do not shift when you shake the container.

Why use cushioning?

Cushioning is used to help a product arrive to its destination in its “as made” condition. It is great to protect items that may be loose in a box or fragile during the shipping process. The goal is to do this the most effective way at the lowest cost so prices do not have to be raised to the end user. Utilizing the right cushioning product and package design will enable you to reduce the size of the corrugated box.

Instapak® Foam Packaging

The InstaPak Simple foam packaging is great for small pick and pack operations. It allows the user to fill just the right amount of foam for each package.

How Does it work?

The Instapak Simple is a small table top system, which is loaded with two 2.5 gallon A and B chemicals. The user then loads the roll of bags into the machine. After that, the user selects what percentage they want the bag to be filled. The machine then fills the bag to the percentage directed, equally with both chemicals. These chemicals then expand and harden into the shape it is placed in.

These bags can be reused if shipping parts or items back and forth.

Check out this video link that shows you exactly how the Instapak Simple works!

Benefits of Instapak Simple

Fast, Easy and Versatile Process for On-Line, On-Site Production of Protective Polyurethane Foam Packages

  • Expands on site by 200 times original volume, reducing freight energy
  • Custom-engineered, reduced package size and weight reduces shipping resources
  • Instapak® RC45 foam contains 25% renewable content
  • SInstapak foam in place is ideal for very expensive or heavy products. It also allows you to automate the production line.
  • Instapak is a good alternative to EPS (expanded polystyrene foam). It provides better cushioning and the tooling is far less expensive.
Other Instapak systems are available for those with higher volume applications. Please contact us!

Mini Air Pak'r

The Mini Air Pak'r provides instant protective packaging and makes bubble air cushions for wrapping, lining and void fill solutions. Now on-demand inflatable packaging is available to everyone!

You no longer need costly extra storage space for pre-made bubble, or protective packaging popcorn. The Mini Air Pak'r is an ideal way to help reduce your carbon footprint. One roll of inflatable packaging film replaces about seven bags of packing peanuts. Our Mini Air Pak'r makes seven different air cushions using the superior cushioning protection of NOVUS® films and the reliable void fill of CELL-O® films.

The large bubble void fill produced by the Mini Air Pak'r, reduces the amount of bubble required - saving money in shipping costs and storage space. It's easy to operate since the machine "reads" an RFID tag in the film and automatically sets the air fill amount and seal temperature. It fits packing tables or can be wall mounted, and carts are available for added mobility.

Who Should Use Mini Air Pak'r?

The Mini Air Pak'r is perfect for anyone shipping just a few packages to 150 boxes a day. Thousands of retailers, shipping companies, and ebay shippers have experienced the advantages of this bubble protective packaging machine. It’s time you did the same. Let us show you how.

Inflatable Dunnage Systems

Kyana Packaging Solutions offers inflatable air cushion or pillow dunnage systems from industry leaders such as Sealed Air and STOROpack for end users at little or no cost, based on the monthly film usage.

These systems produce products that are ideal for cushioning, void-fill, blocking and bracing and wrapping for your fragile products. Inflatable systems from these two industry powerhouses are durable, reliable and efficient ways to quickly pack and protect your products while they are in transit while offering the end user an easy to recycle, clean packaging solution.

Contact Kyana Packaging Solutions for an evaluation of your inflatable needs!

System Paper Solutions

A semi or fully automated paper packaging machine will greatly improve the productivity of your shipping operations. Automated systems are efficient, cost-effective ways to improve ergonomics for your workers, while dramatically improving throughput and offering superior protection to your products in transit.

Kyana Packaging Solutions offers paper dunnage systems from industry leaders such as Sealed Air and STOROpack for end users at little or no cost, based on the monthly paper usage.

Click here to contact Kyana Packaging Solutions today to take advantage of environmentally friendly paper dunnage.


Paper has been the “go to” product for in-the-box packaging for decades. It has a very favorable, easy to use, easy to recycle image. When used properly, paper can have outstanding cushioning effect and compressive strength. Paper can be used for the full range of in the box applications, including: cushioning, void-fill, blocking and bracing and wrapping.

Hand Applied Paper Solutions

Kyana Packaging Solutions offers several cost-effective products for packaging by hand with paper, the two most common being sheets of “newsprint” or rolls of kraft paper. These products can be crumpled into a box to provide void-fill and blocking and bracing for your products as they are in transit. These product, applied by hand are typically used in smaller shipping operations. There are manual kraft paper dispensers with crumplers that can speed the smaller packaging operations. Contact Kyana Packaging Solutions to discuss you needs in manual paper applications for dunnage!

Newsprint and Kraft Paper Rolls

  • A Cost-Effective and Sustainable form of packaging
  • Void Fill
  • Blocking
  • Bracing

Kraft Paper Crumblers

  • An ergonomic solution for manually packaging with rolls of Newsprint and Kraft paper
  • Easy to use
  • Rugged
  • Reduces the opportunities for repetitive strain injuries

Bubble Wrap

Bubble wrap is flexible plastic sheeting containing numerous small air pockets, used in cushioning items during shipment.

It is a common mistake to measure bubble wrap by measuring the width of the bubbles from side to side.

Bubble wrap is actually specified by its height - it is measured from the bottom of the sheet to the highest point of the bubble.

Benefits of Bubble Wrap

  • Surface protection
  • Void fill
  • Light weight thus reducing freight and packaging costs
  • Transparent - enable visual inspections of the product
  • Ease of use
  • Contains good insulation properties
  • Moisture resistant
  • Elastic and strong
  • Easy to trim by hand and trimming machines

Choosing the right bubble size

  • Large, coated (barrier) bubble for heavy or expensive products
  • Small bubble for light cushioning, interleaving, or inexpensive products


A cushioned mailer can be a padded mailer (lined with shredded paper) or bubble lined mailer. Both styles protect the products during shipping.

  • Save Time and Labor - two-step packaging operation vs. six steps with cartons
  • Reduce Packaging Material Costs
  • Eliminate the need for dunnage material and tape
  • Save Postage
  • Total shipping weight is reduced
  • Improve Productivity
  • Save Inventory Space
  • Greater Security - self-seal or heat-seal closures produce a more tamper-evident seal


Custom Sheeting- Kyana has our own custom sheeter. This sheeter has dual jumbo unwind and automatic stackers to help us meet our growing demand to sheet paper, foam, to 60" wide and 72" long. Let us know if you need a specific sized sheet of foam. We'd be glad to supply your sheet goods needs!

Foam Facts

  • Polyethylene (PE) foam is used for light cushioning, interleaving, and surface protection.
  • Polyethylene foam planks (2# density or greater) are good products for blocking and bracing applications where you need to isolate products from moving, but require little cushioning.

Loose Fill

What is loose fill? Loose fill is also known as "packing peanuts" usually made of expanded polystrene.

  • Performance - Provides cushioning protection equal to EPS without the static cling
  • Protection - Keeps products from migrating inside the shipping box throughout distribution
  • Reduces Storage - Better humidity resistance than starch

Other type of Loose Fill

What is loose fill? Loose fill is also known as "packing peanuts" usually made of expanded polystrene.

  • Renature Peanuts - Biodegradable peanuts with low dust generation
  • Anti-Stat Peanuts - These peanuts have a property so they do not conduct static electricity. These are good for electronic devices.