Quick Answer: Air bubble film (bubble wrap) protects fragile items by cushioning against impact, vibration, and abrasion. Small bubbles (10mm diameter) provide surface protection for lightweight or surface-sensitive items; large bubbles (25mm+) absorb impact for heavier or more fragile goods. The correct specification depends on the product weight, fragility, and how it is shipped — not simply on using more layers.
Air bubble film — universally known as bubble wrap — is one of the most recognisable packaging materials in existence, and one of the most frequently misused. Businesses routinely over-specify it (too many layers, bubbles too large for the product) or under-specify it (single layer of small-bubble film around a heavy, fragile item), resulting in either excessive packaging costs or product damage claims.
Understanding the actual protective mechanics of bubble film allows you to make a considered specification rather than defaulting to intuition or habit.
How Air Bubble Film Works
Bubble film works through two mechanisms: cushioning and stand-off. The air-filled bubbles absorb and dissipate impact energy — when a wrapped parcel is dropped or compressed, the bubbles deform elastically and absorb the shock that would otherwise be transmitted directly to the product. The stand-off effect creates a physical gap between the product surface and the outer packaging or other items in the box, preventing surface abrasion during vibration.
The effectiveness of bubble film is primarily determined by bubble size, bubble height, and film thickness. These three variables interact: larger bubbles provide more air volume and therefore more cushioning for heavy impacts; smaller bubbles provide better surface coverage and protection against abrasion and minor impacts; thicker films retain bubble integrity longer during handling.
Small Bubble vs Large Bubble: Which to Use
| Bubble Size | Bubble Diameter | Best Suited For | Not Suitable For |
| Small bubble | 10 mm | Glassware, ceramics, electronics, jewellery | Heavy items — bubbles collapse |
| Medium bubble | 15–20 mm | General fragile goods, mixed shipments | Very heavy or very light items |
| Large bubble | 25–32 mm | Heavy machinery parts, large electronics | Surface-sensitive items — limited coverage |
| Extra large / air column | 40mm+ | Very heavy or high-value fragile goods | Cost-inefficient for light items |
Table 11: Air bubble film selection guide by bubble size, suited applications, and limitations.
Film Thickness and Bubble Retention
Air bubble film is produced in thicknesses ranging from approximately 60 to 120 microns total (film layers on each side of the bubbles). Standard bubble film for general packaging purposes is typically around 70–80 microns. Heavier-duty bubble film at 90–120 microns retains bubble pressure longer under sustained compression — important if wrapped items are stored for extended periods before shipping, or if multiple wrapped items are stacked in boxes.
Bubble film that has lost air pressure in its bubbles provides almost no cushioning. If your packaging workflow involves wrapping items and then holding them in stock before shipping, specify a heavier film or use anti-static bubble film (for electronics), which is produced with a thicker outer layer that maintains bubble integrity for longer.
Perforated Rolls vs Cut-to-Length
Bubble film is available in plain rolls (requiring manual cutting to the required length) and pre-perforated rolls (where the film is scored at regular intervals, allowing clean tearing to a standard length without scissors or a cutter). Pre-perforated rolls reduce packing time and create more consistent wrap lengths across a fulfilment operation.
For operations packing a wide variety of product sizes, plain rolls with a bench-mounted cutter are more versatile. For operations packing a standardised product range, perforated rolls at the correct pitch significantly speed up the packing process.
Avoiding Over-Packing With Bubble Film
Over-packing with bubble film is a genuine and common cost problem. The instinct to wrap fragile items multiple times is understandable, but each additional layer adds material cost, box size requirements, and dimensional weight (which directly affects courier pricing). A single correctly specified layer of the right bubble size is typically more protective than multiple layers of the wrong size.
A useful internal benchmark: if your customer is visibly struggling to unwrap a product, you are over-packing. The goal is adequate protection, not maximum wrapping.
Frequently Asked Questions
Q: What is the difference between small bubble and large bubble wrap?
A: Small bubble wrap (10mm diameter) provides better surface coverage and protection against abrasion and minor impacts — ideal for lightweight, surface-sensitive items like glassware and electronics. Large bubble wrap (25mm+) absorbs larger impact forces, making it suitable for heavier or bulkier fragile items. Using large bubbles on lightweight items provides little surface coverage; using small bubbles on heavy items results in bubble collapse and loss of protection.
Q: How many layers of bubble wrap should I use?
A: One correctly specified layer is sufficient for most applications. For very fragile, high-value, or irregular items, two layers may be warranted — but the second layer should be a different bubble size or orientation to avoid bubble alignment that reduces cushioning. The key variable is the correct bubble size for the product weight, not the number of layers.
Q: Does RB Plast supply air bubble film?
A: Yes. RB Plast supplies air bubble film rolls as part of its protective packaging product range. Contact sales@rbplast.bg or +359 887 584 300 to discuss roll widths, bubble sizes, and volume pricing.
Q: What is anti-static bubble wrap and when do I need it?
A: Anti-static bubble wrap incorporates a chemical treatment that dissipates static electricity, preventing electrostatic discharge (ESD) damage to electronic components and circuit boards. Standard bubble wrap can accumulate and discharge static, potentially damaging sensitive electronics. If you are packaging electronics, PCBs, or components sensitive to ESD, anti-static bubble wrap is required.
To discuss air bubble film specifications and pricing, contact RB Plast at sales@rbplast.bg or +359 887 584 300.
