Affordable, compact machines that produce protective air cushions, bubble wrap and tubes on demand — using film made from 50% recycled content. Save space, time, money, returns and the environment.
View Machines Request Free SampleAir cushion packaging is a modern protective packaging method where a small desktop machine inflates rolls of lightweight plastic film into air-filled cushions, pillows, bubble quilts or tubes. These inflated cushions are then used inside boxes to protect products during shipping — filling empty space (void fill), wrapping fragile items, or cushioning products against impact.
If you're currently using bubble wrap, loose fill peanuts, scrunched-up paper or foam chips to protect your products in transit, air cushion packaging does the same job — but faster, cheaper and with less storage space required. A single roll of flat film, about the size of a large kitchen roll, inflates into the equivalent of approximately 6 bags of loose fill. That's a genuine game-changer for businesses with limited warehouse space.
The process is simple. You load a roll of flat film into the machine, plug it in, and press start. The machine feeds the film through heated sealing bars while pumping air into each cushion. The inflated cushions come out on a continuous perforated strip — you just tear off what you need for each parcel. The whole process takes seconds, and most machines require zero training to operate. Plug and play, literally.
Air cushion machines are used by businesses of all sizes across e-commerce, retail, logistics, pharmaceutical, electronics, gift and homeware sectors. They're particularly valuable for businesses that ship fragile or high-value items and want to reduce damage rates, or businesses that are looking to move away from bulky, space-consuming materials like loose fill or pre-made bubble wrap.
If you're a startup or small business shipping even 5-10 parcels a day, an entry-level air cushion machine will pay for itself within weeks through material cost savings alone. If you're a larger operation, higher-speed models with accessories like winders and hopper trolleys can integrate into a fast-paced packing line.
Forever Green air cushion films are made from 50% recycled content, which means 50% less virgin plastic is needed to produce each roll. Once inflated, the cushions are 99% air and just 1% material — it genuinely doesn't get much greener than packing with air.
The films are 100% recyclable and exempt from the UK Plastic Packaging Tax (which applies to packaging with less than 30% recycled content). We also run a free Return 2 Recycle service: we send you prepaid mailers, you send back used film, and we ensure it's properly recycled.
And with every order, we plant a tree through our partnership with Ecologi.
Forever Green was born to make the benefits of packaging systems affordable to smaller businesses and cheaper for larger businesses. Historically, only high-volume users could accommodate minimum order quantities and high capital expenditure. Here, you can buy whatever material you need, when you need it, for the system that suits you.
Simple, reliable and in everyone's corner. Low cost that soon pays for itself with cheaper ongoing material costs, while offering quicker packing and saved space versus bulky materials.
Best for: Startups and small businesses shipping up to 50 parcels/day
Your competitive all-rounder, compatible with efficiency-gaining accessories like winders. Extra machine features lead your packing team the right way.
Best for: Growing businesses shipping 50-200+ parcels/day
Does everything the others do, plus compatible with multiple hoppers and 800mm wide bubble. More technical or demanding packing frontlines can rely on this rare breed.
Best for: High-volume operations and distribution centres
Not sure which machine is right? That's exactly what we're here for. Talk to Tom — he'll ask about your volumes, products and space, and give you an honest recommendation. If a machine isn't the right fit for you, he'll say so.
Each machine works with the widest range of Forever Green high-quality, environmentally responsible films. All our films contain 50% recycled content and are 100% recyclable.
| Film Type | Size | Roll Length | Best For |
|---|---|---|---|
| 200mm x 200mm Cushion | 200 x 200mm | 500m | General void fill — most versatile size |
| 200mm x 100mm Cushion | 200 x 100mm | 500m | Smaller boxes, tighter void spaces |
| 400mm Bubble | 400mm wide | 350m | Wrapping fragile items — glass, electronics, ceramics |
| 800mm Bubble | 800mm wide | 250m | Larger fragile items (Navy Seal compatible) |
| 400mm Quilt | 400mm wide | 350m | Surface protection, interleaving, wrapping |
| 400mm x 50mm Tube | 400 x 50mm | 350m | Blocking, bracing & edge protection |
Air is the ultimate cushioning and protection for your products. The recycled and recyclable films are just 1% of the actual packaging material once the machine has filled it with 99% air. It doesn't get much greener than packing with air — aka nothing.
We get it — switching to a new packaging system is a decision. Here's how air cushion packaging stacks up against the most common alternatives on the metrics that actually matter.
| Factor | Air Cushions | Bubble Wrap | Loose Fill Peanuts | Scrunched Paper |
|---|---|---|---|---|
| Storage space needed | ★ Minimal — flat rolls | Large — bulky rolls | Very large — bags | Moderate — rolls or sheets |
| Cost per parcel | ★ Lowest | Medium-high | Medium | Medium |
| Speed of packing | ★ Fastest — on demand | Manual tearing/cutting | Slow — scooping & settling | Manual scrunching |
| Mess factor | ★ Zero mess | Minimal | High — static, spillage | Moderate — paper dust |
| Protection quality | ★ Excellent | Good | Adequate (settles over time) | Adequate |
| Recyclable? | ★ Yes — 100% | Limited | Varies | Yes |
| Recycled content | ★ 50% | Usually 0% | Varies | Varies |
| Weight added to parcel | ★ Virtually none | Light | Light-moderate | Moderate |
Catches inflated cushions as they come off the machine, keeping your packing bench tidy and your cushions within arm's reach. Wheels let you move it around your packing area.
Automatically winds inflated bubble film into neat rolls for easy storage and dispensing. Essential for operations producing large quantities of bubble wrap.
We also offer free loan machines for qualifying businesses and efficiency-gaining equipment packages. Contact Tom to discuss your options →