Abstract: Free-flowing dunnage of molded pulp pieces (10), having random non-nestable shapes to insure the free-flowing characteristic, is made by a method and apparatus involving partially drying pulp fibers on a forming-die screen (38) to form intermediate dish-shaped pieces, form-free removal of such pieces from the screen, and thereafter drying them free of form support to obtain random shapes. One preferred embodiment involves blowing intermediate pieces from the screen onto a conveyor (50) for subsequent drying, such blowing and landing altering the intermediate piece shapes to enhance randomness in the shapes of the dunnage pieces, and another involves using heated air for partial drying.

Abstract: Free-flowing dunnage packaging material is made from molded pulp to form non-planar, dish-like shapes, each having a hollowed central void preferably surrounded by beaded edges. The dunnage pieces are preferably manufactured by a free of form process which results in random shaping, thereby avoiding nesting and maintaining package volume.