It's Like Shipping Your Products in a Suit of Air-Filled Armor.

No other product packaging method provides more shipping damage protection than Aerocell inflatable structural packaging

And no other eco-friendly, US-manufactured packaging option offers more 3-D solutions perfectly tailored to your product. 

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The ABCs of Gs
Patented pressure-adjusting columns of air provide the ultimate G-force shock protection.

Let’s face it, gravity is not a shipper’s friend. At least not when it comes to providing breakage protection for your products during shipping and handling.

That’s where Aerocell’s patented, pressure-adjusting air columns make all the difference.

Maximum shock protection for your product is provided by enclosing and completely surrounding it with independent, multi-sized columns of pressurized air that absorb nearly all potential G-forces from every angle. 


It means products ranging from fragile art glass, ceramics and bottles, to electronic devices, computers and delicate components can be shipped with complete confidence, reducing returns due to handling damage to nearly zero. 

Using Aerocell inflatable structural packaging is like shipping your products in a suit of air-filled armor.



Near-Perfect Protection is Only One of the Benefits of Using Aerocell Packaging...



Inflatable Packaging for Nyco

10,000 shipments, zero damage returns.    

Inflatable Structural Packaging FAQ


  • Where is Aerocell Manufactured?
    • 100% of all Aerocell Products are manufactured in the United States.  Our dedicated and passionate team, based in Batavia, IL, makes every product we sell. And every raw material we use comes from U.S. producers.
  • How is Aerocell shipped?
    • We ship Aerocell flat, un-inflated. The customer then inflates it at their point of use.  As a result, large volumes of our product take up very small amounts of space. A pallet of Aerocell is equivalent to a truckload of competitive packaging options.  This means Aerocell lowers your freight costs and uses a fraction of your inventory space.
  • How does Aerocell work?
    • A pneumatic inflation fixture, called an Aeroport,™ is the source of compressed air that inflates Aerocell, typically in 1-3 seconds. Some customers use a portable compressor and others use in-house compressed air.
  • How long will Aerocell stay inflated?
    • Aerocell's high-nylon, co-extruded film provides maximum chamber air holding time.  Aerocell typically remains fully inflated for 30+ days. 
  • Will Aerocell protect my damageable product?
    • When we say Aerocell is like surrounding your product in a suit of air-filled armor, we mean it. Aerocell completely protects such delicate and fragile items as glass, electronics, plastic containers, and items with contents under pressure. And it does so in some of the harshest environments. See our case studies for real-world proof. 
  • Is Aerocell Recyclable?
    • Yes, 100%! But more importantly, Aerocell reduces to less than 5% of its inflated volume, significantly reducing recycling shipping costs. For one customer, Aerocell reduced the recycling footprint by 195% when they switched from extruded foam.
  • Is Aerocell Price Competitive?
    • Aerocell's costs are directly competitive with the most commonly used packaging mediums.
  • Does Aerocell sell standard or custom items?
    • Both. Aerocell has a wide range of standard solutions for such products as toner cartridges, bottles and electronics.  Wherever we don’t have an off-the-shelf solution, we will quickly and cost-effectively develop a custom-designed product to meet your needs.  Minimum quantities for custom products can be as low as 2500-5000 pieces. Standard item minimums can be as low as 150-300 pieces.
  • Are there high costs of molds, tooling to make a custom product?
    • No. We can often produce a product without any upfront cost to the customer.  Whenever custom solutions do require custom tooling, our start-up costs are always highly affordable.
  • How do I submit a custom product for design and how long does it take?
    • After our initial discussion with a customer regarding project scope, goals, current packaging, requirements and volume needed, we usually require a sample of the product to be packaged. We then generate a prompt RFQ, typically within 5-7 working days, depending on project complexity and scope. Start an RFQ, or request a sample today.
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If You Need to Ship It, Aerocell Can Protect It.


About Aerocell

Aerocell began in 2007. Mike Baines, a veteran of the packaging industry for more than 25 years, saw inflatable structural packaging as the perfect eco-friendly solution to safely shipping any product anywhere in today's e-commerce economy.

Aerocell is the only U.S. manufacturer of Inflatable Structural Packaging. The company provides Design, Prototype Sampling, Manufacturing and Distribution all from one domestic location.