Looking for an Alternative to Bubble Wrap? Discover HexcelWrap

Protect your products with paper-based cushioning that works perfectly alongside right-sized cardboard boxes.

At ASC Direct, we're big believers in using the right amount of packaging.

Choosing a custom-sized cardboard box can significantly reduce unnecessary empty space, meaning less material is needed to pack and protect your products.

But sometimes the right-sized box isn't enough on its own.

Fragile, delicate, valuable or irregularly shaped products may still need an additional layer of protection during storage and delivery. Traditionally, businesses have turned to plastic bubble wrap for this.

There is another option.

HexcelWrap® provides protective paper-based cushioning without relying on traditional plastic bubble wrap.

What is HexcelWrap®?

HexcelWrap is a die-cut kraft paper wrapping material that expands as it is pulled from the roll.

The paper opens into a three-dimensional honeycomb structure which can be wrapped around a product to provide cushioning and protection inside your cardboard box.

The interlocking honeycomb design also means the material grips onto itself as it is wrapped, reducing the need for additional tape.

Why use HexcelWrap instead of bubble wrap?

Plastic bubble wrap has been widely used because it's lightweight, convenient and provides good cushioning.

However, businesses are increasingly looking at ways of reducing the amount of plastic used within their packaging.

Switching from plastic bubble wrap to a paper-based wrapping solution is one relatively simple change businesses can make.

HexcelWrap gives you the protection you need while allowing you to create a predominantly paper and cardboard-based packaging solution.

Right-sized boxes + the right protection

We manufacture custom-sized cardboard boxes because reducing unnecessary space inside a package has several advantages.

A box that fits your product more closely can:

• Reduce the amount of cardboard required
• Reduce unnecessary void space
• Reduce the amount of additional packing material required
• Keep products more securely positioned
• Potentially reduce the overall size of your parcel

However, right-sized packaging doesn't necessarily mean using no protective packaging at all.

If you're sending glassware, ceramics, cosmetics, electronics, gifts or other fragile products, an additional layer of cushioning can help protect the product from knocks and movement during transit.

The aim shouldn't simply be to eliminate protective packaging. It should be to use the right amount of the right material.

That's where HexcelWrap can help.

What are the benefits of HexcelWrap®?

1. Helps protect fragile products

When expanded, the honeycomb paper creates a cushioning layer around your product.

It conforms to different shapes, making it particularly useful for fragile or irregular items that need additional protection inside a box.

2. A paper-based alternative to plastic bubble wrap

If you're currently using bubble wrap, HexcelWrap provides an easy way to reduce the amount of plastic in your packaging.

Combine it with an ASC Direct corrugated cardboard box and you can create a packaging solution based predominantly around paper and cardboard materials.

3. Creates a great unboxing experience

Packaging isn't only about getting a product safely from A to B.

For ecommerce businesses, it's also one of the few physical interactions your customer may have with your brand.

The honeycomb paper creates an attractive, premium presentation when the customer opens their parcel – particularly useful for gifts, cosmetics, homeware and other presentation-sensitive products.

4. No tape required

One of the clever features of HexcelWrap is the way the expanded honeycomb cells interlock.

The material grips onto itself as it is wrapped around the product, so there's normally no need to secure every item with additional tape.

That can make packing quicker while also reducing the number of different materials used.

5. Suitable for different shapes and sizes

Not everything you send is perfectly square.

HexcelWrap can conform around different product shapes, allowing you to add protection exactly where it's required.

Do I still need void fill?

There's an important difference between wrapping a product and filling empty space inside a box.

HexcelWrap is primarily used to wrap and cushion the product.

If there is significant empty space remaining inside your box, you may also need suitable void fill to prevent the wrapped product from moving around during transportation.

Better still, consider whether you can reduce that space in the first place.

With the ASC Direct Box Builder, you can enter the dimensions you require and order cardboard boxes manufactured specifically to your chosen size.

A closer-fitting box combined with appropriate paper-based protection can reduce unnecessary packaging while still helping your products arrive safely.

Is it time to move away from plastic bubble wrap?

If your business currently sends products wrapped in plastic bubble wrap, it may be worth reviewing whether you still need to use it.

You don't have to compromise on product protection to reduce your reliance on plastic packaging.

By combining:

A right-sized cardboard box + the right amount of HexcelWrap®

you can create a simple, effective packaging solution designed around both product protection and reducing unnecessary packaging.

Ready to make the switch?

Explore HexcelWrap® and our range of eco packaging, or use our Box Builder to create a cardboard box made to the dimensions you need.

James Palfrey-Smith is the General Manager at ASC Direct with extensive experience in both operations and sales. James is passionate about solving packaging problems, delivering fast customer support, and building lasting relationships. Outside of work, he enjoys outdoor activities like hiking and skiing. A fan of real ale and business podcasts, he continuously seeks personal and professional growth. 

Find James on  Linkedin 

Find out more about James