Bubble wrap – we are constantly surrounded by this name when it comes to packaging and safekeeping. The typical plastic sheeting with numerous small air pockets has become more than a need and we all go by its virtues and depend on these for packing almost everything.

Its amazing features and qualities as a wrapping solution like being lightweight, cushioning, reusable, easily storable, anti-abrasion, water resistant and more than everything being apt for any type of material, make it so popular.

Manufacturing process of Bubble Film and Bags

  1. It starts with polythene resin formed into beads of a size of a pea gravel (what you call bubble later on).
  2. A cylinder with a screw runs its entire length rotating 180 degree to melt and squeeze to take shape of a bubble.
  3. A layer of plastic film is wrapped around the drum and the cylindrical holes are punched and attached to the sheet and air is sealed.
  4. To provide it a sustainable shape and strengthened base, extra layer of lamination sheet is added around it.
  5. To make sure that the air doesn’t leak from the bubbles they used to put on Saran Coating to seal it well. Later on, it was replaced by an advanced method to create air retention barrier and make it last long.
  6. Then they are provided the shape of utility they are going to be used in – as a bubble wrap, film or bag.

History of Bubble Wrap

Bubble Wrap was bought into existence by Alfred Fielding and Marc Chavannes, in 1957. As they started industrially pitching the product as a cushioning and wrapping material and their idea got hit, they went on to incorporate a company named Sealed Air Corporation in 1960. This led to a series of big accomplishments and stablished it as a benchmark novelty product that is used globally as a packaging solution today.


Low density polythene

Recycled polythene


Bubble Diameter: 6mm (0.25″) to 25mm (1″)

Bubble Height: up to 4mm

Types of Bubble Wraps

Bubble Bags: Used for outer wrapping protection and carrying and is highly popular with packers and movers.

  1. Standard Bubble Wrap Rolls: Used for cushioning light weight products, inter-layering and surface protection.
  2. Medium Duty Rolls: Used for medium weight goods to be moved to a moderate distance and protected against above-average damage threats.
  3. Heavy Duty Rolls: For covering and protecting heavier items like large compressors, motors, and heavy equipment.
  4. Bubble Envelops: For sending small and flat supplies that can slip-fit into small size mailers – like DVDs, jewellery, electronics, and miniature artefacts.

Top Benefits of Bubble Wrap

  • Bubble wrap is lightweight and therefore reduces freight and transportation costs
  • Cheap Bubble Wrap Rolls are available readily everywhere
  • Bubble Pallet Wraps are used for different packaging purposes and needs
  • These are moisture resistant and have good insulation properties
  • Well protects goods against abrasion and breakage
  • Easy-to-use and apply by using basic tools and aids

So, these are all the basics of what bubble wrap is all about, how it is made and what are its benefits as a packaging product.