The Ultimate Guide to Bubble Wrap Sizes and Layers

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How do bubble size, layers, and roll configurations impact bubble wrap performance?

When it comes to protective packaging, bubble wrap is one of the most reliable and versatile solutions available. Its lightweight cushioning, strength, and adaptability make it ideal for protecting products of all shapes and sizes across a wide range of industries. But not all bubble wrap is the same. Bubble size, the number of layers, and roll configuration all play an important role in determining performance.
The Phoenix Bubble Wrap range is designed to suit a variety of packaging requirements, from light surface protection through to heavy-duty cushioning for larger or irregularly shaped goods. Understanding these differences can help you choose the right bubble wrap for your application.

Why Bubble Size Matters

Bubble size directly impacts the level of cushioning, protection, and void fill the material provides.

10mm bubbles are ideal for delicate and lightweight items. They provide gentle cushioning and help protect surfaces from scratches and abrasions. This size is well-suited to products such as cosmetics, small glassware, collectibles, decorative items, and other fragile keepsakes.

20mm bubbles offer a balanced combination of cushioning and versatility. They are a popular general-purpose option for a wide range of products and are suitable for everyday packaging needs.

30mm bubbles provide greater shock absorption and impact resistance. They are best suited to heavier, bulkier, or awkwardly shaped items that require more robust protection during handling, storage, and transit.

The Importance of Layers

Bubble wrap performance is influenced not only by bubble size, but also by the number of layers used in its construction.

2-Layer Bubble Wrap

This is the traditional style of bubble wrap, featuring a single layer of bubbles bonded to a smooth backing film. It is lightweight, economical, and highly effective for general packaging applications.
2-layer bubble wrap is available in 10mm, 20mm, and 30mm bubble sizes, with roll lengths ranging from 50 metres to 200 metres. It is ideal for wrapping smaller items, interleaving products, or adding protective padding inside cartons.

3-Layer Bubble Wrap 

For applications requiring greater durability, 3-layer bubble wrap offers enhanced strength and performance. Often referred to as “Twin Skin”  with an additional outer layer that improves puncture resistance and compression strength, making it better suited to demanding packaging environments.
Twin Skin or 3-layer bubble wrap is also available in 10mm, 20mm, and 30mm bubble sizes, with roll lengths from 50 metres to 200 metres. It is particularly effective for void fill, bulkier goods, and high-value products that need extra protection in transit.

Roll Configurations and Customisation Options

Every packaging operation is different, which is why roll configuration can significantly affect efficiency and material usage. Get Packed Packaging offers a range of customisation options to help businesses package more effectively.
Slit rolls are available in custom widths for more precise application, helping reduce waste and improve packing speed.
Perforated rolls are pre-cut for easy tear-off use, saving time and eliminating the need for knives or cutting tools.
Bubble bags and bubble tubing provide a convenient solution for packaging fragile or irregularly shaped items, offering quick and consistent protection.
Custom micron options are also available, from standard grades through to super heavy-duty specifications of up to 250 microns, depending on the application.

Bubble Wrap Solutions for Different Industries

The Phoenix Bubble Wrap range is designed to support a wide variety of industries and packaging environments.
In e-commerce, lightweight 10mm and 20mm bubble wraps provide dependable protection without adding unnecessary bulk or freight costs.
For industrial packaging, heavier duty 20mm and 30mm bubble wraps help protect machinery, components, and larger equipment during storage and transport.
In retail and fulfilment, slit rolls, bubble bags, and tubing can streamline the packing of fragile goods such as cosmetics, ceramics, glassware, and collectibles.

A Focus on Sustainability

As businesses place greater emphasis on environmentally responsible packaging, bubble wrap solutions also continue to evolve. The Phoenix 50% recycled bubble wrap range is designed to deliver reliable protection while supporting more sustainable packaging practices. Phoenix is Australia’s first bubble wrap featuring a post-consumer recycled content blend. This specially engineered material contains 50% recycled content, including at least 25% post-consumer waste and 25% post-industrial recycled material—delivering reliable protection with a reduced environmental impact.
This includes lightweight materials that can help reduce freight weight and shipping-related emissions, as well as recyclable materials where applicable, helping businesses align with their sustainability goals without compromising on performance.

Choosing the Right Bubble Wrap

Selecting the right bubble wrap depends on the type of product being packed, the level of protection required, and the demands of your packing process.

Bubble Size	Best For	Available Layers
10mm	Fragile and small items	2-Layer, 3-Layer
20mm	General Purpose Protection	2-Layer, 3-Layer
30mm	Heavy duty or irregularly shaped items	2-Layer, 3-Layer

For businesses needing even more flexibility, slit rolls, perforated rolls, bubble bags, and bubble tubing offer tailored options to suit specific packing applications.

• Slit Rolls: Custom widths for precise packaging, reducing waste and improving efficiency.
• Perforated Rolls: Pre-cut sections for hassle-free use, eliminating the need for cutting tools.
• Bubble Bags and Tubing: Perfect for packing irregularly shaped or fragile items, offering added convenience and protection.
• Custom Micron Options: From standard to super-heavy-duty (up to 250μm), tailored for specific applications

Whether it's everyday dispatch or specialised industrial packaging, Get Packed Packaging has a bubble wrap solution for you. Whether you are protecting delicate glassware, filling voids in cartons, or cushioning heavy equipment, our versatile range helps keep your products safe and secure.
Ready to improve your packaging performance? Explore our full range of bubble wrap solutions or contact our team for expert advice and personalised recommendations.