Abstract: A compact dunnage conversion machine includes a converging chute with a restricted inlet, a powered feed assembly with a sealed gearbox, a plurality of interchangeable power supplies, and a restricted outlet chute. The converter can convert a sheet stock material into dunnage for use in packaging one or more objects in a container. The restricted inlet and outlet make it more difficult for foreign objects to enter the converter and disrupt the conversion process. The sealed gearbox interposed between the driving elements of the feed assembly and an electric motor facilitates maintenance and repair of the feed assembly, while also protecting the gears therein. Finally, the power supplies provide electrical power to the motor and can include an electrical storage device, such as a battery, or an alternating-current-to-direct-current converter which is connectable to a source of electricity for supplying that electricity to the motor in an acceptable form.

Abstract: A packaging method includes the steps of (a) detecting whether a height (104) of contents (105) in a container (106) exceeds a predetermined height (112), and (b) indicating how much dunnage to dispense based on predetermined criteria, including whether a detected height exceeds a predetermined height that is less than a height of the container. The indicating step includes indicating a quantity of dunnage to dispense selected from a plurality of predetermined quantities of dunnage. If no detected height is greater than the predetermined height, the indicating step includes indicating that a regular amount of dunnage should be dispensed. And if a detected height is greater than the predetermined height, the indicating step includes indicating that either zero or less than the regular amount of dunnage should be dispensed. The detecting step also can include detecting whether any contents in the container have a height above the height of the container.

Abstract: A packaging method includes the steps of (a) detecting whether a height (104) of contents (105) in a container (106) exceeds a predetermined height (112), and (b) indicating how much dunnage to dispense based on predetermined criteria, including whether a detected height exceeds a predetermined height that is less than a height of the container. The indicating step includes indicating a quantity of dunnage to dispense selected from a plurality of predetermined quantities of dunnage. If no detected height is greater than the predetermined height, the indicating step includes indicating that a regular amount of dunnage should be dispensed. And if a detected height is greater than the predetermined height, the indicating step includes indicating that either zero or less than the regular amount of dunnage should be dispensed. The detecting step also can include detecting whether any contents in the container have a height above the height of the container.

Abstract: An improved packaging system (10) includes a packaging line that guides containers in a downstream direction, a sensor (12) that can identify a dimension of a container on the packaging line, a dunnage dispenser (14) on the packaging line downstream of the sensor to dispense dunnage to a void volume in a container, and a container closer (16) downstream of the dunnage dispenser (14) to close containers on the packaging line downstream of the dunnage dispenser. The container closer (16) includes an adjustable member (20), and is in communication with the sensor to (12) adjust the adjustable member (20) based on the identified dimension of the container. The system thus includes a way to identify the size of the container before the container reaches the container closer. The container closer can adjust for the container's size before the container arrives, speeding up the container closing operation.

Abstract: A compact dunnage conversion machine includes a converging chute with a restricted inlet, a powered feed assembly with a sealed gearbox, a plurality of interchangeable power supplies, and a restricted outlet chute. The converter can convert a sheet stock material into dunnage for use in packaging one or more objects in a container. The restricted inlet and outlet make it more difficult for foreign objects to enter the converter and disrupt the conversion process. The sealed gearbox interposed between the driving elements of the feed assembly and an electric motor facilitates maintenance and repair of the feed assembly, while also protecting the gears therein. Finally, the power supplies provide electrical power to the motor and can include an electrical storage device, such as a battery, or an alternating-current-to-direct-current converter which is connectable to a source of electricity for supplying that electricity to the motor in an acceptable form.

Abstract: A compact dunnage conversion machine includes a converging chute with a restricted inlet, a powered feed assembly with a sealed gearbox, a plurality of interchangeable power supplies, and a restricted outlet chute. The converter can convert a sheet stock material into dunnage for use in packaging one or more objects in a container. The restricted inlet and outlet make it more difficult for foreign objects to enter the converter and disrupt the conversion process. The sealed gearbox interposed between the driving elements of the feed assembly and an electric motor facilitates maintenance and repair of the feed assembly, while also protecting the gears therein. Finally, the power supplies provide electrical power to the motor and can include an electrical storage device, such as a battery, or an alternating-current-to-direct-current converter which is connectable to a source of electricity for supplying that electricity to the motor in an acceptable form.

Abstract: A packaging method includes the steps of (a) detecting whether a height (104) of contents (105) in a container (106) exceeds a predetermined height (112), and (b) indicating how much dunnage to dispense based on predetermined criteria, including whether a detected height exceeds a predetermined height that is less than a height of the container. The indicating step includes indicating a quantity of dunnage to dispense selected from a plurality of predetermined quantities of dunnage. If no detected height is greater than the predetermined height, the indicating step includes indicating that a regular amount of dunnage should be dispensed. And if a detected height is greater than the predetermined height, the indicating step includes indicating that either zero or less than the regular amount of dunnage should be dispensed. The detecting step also can include detecting whether any contents in the container have a height above the height of the container.

Abstract: A packaging system 100 includes a controller 102, an input device 104 in communication with the controller 102 that identifies one or more characteristics of the container, and a manual input device 106 in communication with the controller 102 that provides multiple input options for selection by a packer. The input options represent relative degrees to which a container is filled by one or more objects to be packaged. The controller 102 provides an output signal indicating a quantity of dunnage to dispense to the container based on the selected input option and the one or more identified characteristics of the container. Once the controller receives the container characteristics information, as well as the selected input option representing the relative degree to which the container is filled by the objects to be packaged, the controller can determine the number and lengths of dunnage strips that need to be provided to fill the remaining void in the container.

Abstract: An improved packaging system (10) includes a packaging line that guides containers in a downstream direction, a sensor (12) that can identify a dimension of a container on the packaging line, a dunnage dispenser (14) on the packaging line downstream of the sensor to dispense dunnage to a void volume in a container, and a container closer (16) downstream of the dunnage dispenser (14) to close containers on the packaging line downstream of the dunnage dispenser. The container closer (16) includes an adjustable member (20), and is in communication with the sensor to (12) adjust the adjustable member (20) based on the identified dimension of the container. The system thus includes a way to identify the size of the container before the container reaches the container closer. The container closer can adjust for the container's size before the container arrives, speeding up the container closing operation.

Abstract: A packaging system (100) includes a controller (102), an input device (104) in communication with the controller (102) that identifies one or more characteristics of the container, an illustration with indicia representing different degrees of fill for a container; and a manual input device (106) in communication with the controller (102) for inputting an estimated degree of fullness of the packing container having one or more articles to be packed correlated with the indicia in the illustration. The controller (102) provides an output signal indicating a quantity of dunnage to dispense to the container based on the input estimated degree of fullness and the one or more identified characteristics of the container. Then the controller can determine the amount of dunnage that needs to be provided to fill the remaining void in the container, and the controller can signal a dunnage dispenser (110) to dispense the determined amount of dunnage.

Abstract: A compact dunnage conversion machine includes a converging chute with a restricted inlet, a powered feed assembly with a sealed gearbox, a plurality of interchangeable power supplies, and a restricted outlet chute. The converter can convert a sheet stock material into dunnage for use in packaging one or more objects in a container. The restricted inlet and outlet make it more difficult for foreign objects to enter the converter and disrupt the conversion process. The sealed gearbox interposed between the driving elements of the feed assembly and an electric motor facilitates maintenance and repair of the feed assembly, while also protecting the gears therein. Finally, the power supplies provide electrical power to the motor and can include an electrical storage device, such as a battery, or an alternating-current-to-direct-current converter which is connectable to a source of electricity for supplying that electricity to the motor in an acceptable form.

Abstract: A packaging method includes the step of comparing a total package weight to a freight rate schedule and thereby determining a normal freight rate. The total package weight includes the weight of a container (22), an article (24) to be shipped and a normal amount of dunnage. If predetermined criteria are met, the method also includes the step of reducing the amount of dunnage dispensed below that of the normal amount of dunnage such that the total package weight falls within a freight rate that is less than the normal freight rate. The predetermined criteria include one or more of a predetermined percentage above a change in freight rate, a predetermined weight above a threshold weight for an increase in freight weight, and dunnage requirements including void-volume, degree of fill for the void-volume, type of article, weight of article and type of dunnage.

Abstract: A packaging system (100) includes a controller (102), an input device (104) in communication with the controller (102) that identifies one or more characteristics of the container, an illustration with indicia representing different degrees of fill for a container; and a manual input device (106) in communication with the controller (102) for inputting an estimated degree of fullness of the packing container having one or more articles to be packed correlated with the indicia in the illustration. The controller (102) provides an output signal indicating a quantity of dunnage to dispense to the container based on the input estimated degree of fullness and the one or more identified characteristics of the container. Then the controller can determine the amount of dunnage that needs to be provided to fill the remaining void in the container, and the controller can signal a dunnage dispenser (110) to dispense the determined amount of dunnage.

Abstract: A method of converting a sheet stock material into a relatively less dense dunnage product includes the step of supplying the sheet stock material to a conversion mechanism for converting the sheet stock material into the dunnage product by permanently deforming the sheet stock material into a nonplanar configuration to provide the dunnage product with a density less than the density of the stock material from which it is formed. The sheet stock material comprises one or more plies of paper having a caliper no less than about 3.5 points (about 0.089 millimeter) or a bulk caliper no less than about 3.4 points (about 0.086 millimeter) for a basis weight no greater than about 32 pounds (about 86 grams per square meter) and when a moisture content is no greater than about 10%.

Abstract: A packaging method includes the steps of (a) detecting whether a height (104) of contents (105) in a container (106) exceeds a predetermined height (112), and (b) indicating how much dunnage to dispense based on predetermined criteria, including whether a detected height exceeds a predetermined height that is less than a height of the container. The indicating step includes indicating a quantity of dunnage to dispense selected from a plurality of predetermined quantities of dunnage. If no detected height is greater than the predetermined height, the indicating step includes indicating that a regular amount of dunnage should be dispensed. And if a detected height is greater than the predetermined height, the indicating step includes indicating that either zero or less than the regular amount of dunnage should be dispensed. The detecting step also can include detecting whether any contents in the container have a height above the height of the container.

Abstract: A packaging system 100 includes a controller 102, an input device 104 in communication with the controller 102 that identifies one or more characteristics of the container, and a manual input device 106 in communication with the controller 102 that provides multiple input options for selection by a packer. The input options represent relative degrees to which a container is filled by one or more objects to be packaged. The controller 102 provides an output signal indicating a quantity of dunnage to dispense to the container based on the selected input option and the one or more identified characteristics of the container. Once the controller receives the container characteristics information, as well as the selected input option representing the relative degree to which the container is filled by the objects to be packaged, the controller can determine the number and lengths of dunnage strips that need to be provided to fill the remaining void in the container.

Abstract: A compact dunnage conversion machine includes a converging chute with a restricted inlet, a powered feed assembly with a sealed gearbox, a plurality of interchangeable power supplies, and a restricted outlet chute. The converter can convert a sheet stock material into dunnage for use in packaging one or more objects in a container. The restricted inlet and outlet make it more difficult for foreign objects to enter the converter and disrupt the conversion process. The sealed gearbox interposed between the driving elements of the feed assembly and an electric motor facilitates maintenance and repair of the feed assembly, while also protecting the gears therein. Finally, the power supplies provide electrical power to the motor and can include an electrical storage device, such as a battery, or an alternating-current-to-direct-current converter which is connectable to a source of electricity for supplying that electricity to the motor in an acceptable form.

Abstract: A system, and associated components and methodology, that automatically acquires data representative of the space left in each of a series of containers (32) in which one or more articles have been placed for packaging, and dispenses a controlled amount of dunnage material based on that data from a selected one of a plurality of dunnage dispensers (12). The system includes void volume data acquisition apparatus (11) for acquiring void volume data for the containers sequentially supplied thereto and for associating the sequentially acquired void volume data with the container. The system also includes a plurality of dunnage dispensers remotely located relative to the void volume data acquisition apparatus to dispense a controlled amount of dunnage material for insertion into one of the containers selectively transported to that dispenser from the void volume data acquisition apparatus.

Abstract: A motor-free dunnage conversion system comprises a housing (20) having a dispensing outlet (40) through which sheet stock material (34) can be pulled by a user to form a strip of dunnage. The housing (20) has a forming member (44, 50) with circumferentially converging side walls that gradually inwardly gather and crumple the sheet stock material as it is pulled therethrough. The system can also include one or more of a stand having a support mounted thereto for supporting a supply of stock material, a repositionable member (22) supporting the forming member (44, 50), a guide member at the upstream end of the housing to guide the stock material from a supply to the forming member, and a catch device operative upon movement of the dunnage strip relative thereto to catch and hold the strip for severing a dunnage product therefrom.

Abstract: A packaging method includes the step of comparing a total package weight to a freight rate schedule and thereby determining a normal freight rate. The total package weight includes the weight of a container (22), an article (24) to be shipped and a normal amount of dunnage. If predetermined criteria are met, the method also includes the step of reducing the amount of dunnage dispensed below that of the normal amount of dunnage such that the total package weight falls within a freight rate that is less than the normal freight rate. The predetermined criteria include one or more of a predetermined percentage above a change in freight rate, a predetermined weight above a threshold weight for an increase in freight weight, and dunnage requirements including void-volume, degree of fill for the void-volume, type of article, weight of article and type of dunnage.