Abstract: A method of producing air cushions with an air cushion machine for cushioning at least one item to be shipped in a box comprises the steps of determining a void volume defined by a difference between a volume of the box and a volume of the at least one item to be shipped in the box, and producing a quantity of air cushions with the air cushion machine having a total air cushion volume, the total air cushion volume being equal to the void volume.

Abstract: Apparatus for supplying multiple foam machines with foam precursor chemicals. The apparatus comprises first and second totes having a top opening and a bottom drain and containing first and second foam precursor chemicals, first and second supply lines connected to the bottom drains of the first and second totes and in fluid communication with first and second sets of batcher stands, and first and second sets of batcher pumps each of which is positioned in a respective one of the first and second sets of batcher stands. Each batcher pump is adapted to be in fluid communication with a respective one of the foam machines.

Abstract: Apparatus for supplying multiple foam machines with foam precursor chemicals. The apparatus comprises first and second totes having a top opening and a bottom drain and containing first and second foam precursor chemicals, first and second supply lines connected to the bottom drains of the first and second totes and in fluid communication with first and second sets of batcher stands, and first and second sets of batcher pumps each of which is positioned in a respective one of the first and second sets of batcher stands. Each batcher pump is adapted to be in fluid communication with a respective one of the foam machines.

Abstract: A machine for forming foam cushions comprises a web of film comprising a pair of film panels positioned face to face and having first and second lengthwise edges, and first and second foam dispensing assemblies positioned to dispense foam between the film panels, each foam dispensing assembly comprising first and second valves that dispense first and second foam components, respectively, the valves positioned so that respective foam component streams exiting the valves intersect.

Abstract: A machine for forming foam cushions comprises a web of film comprising a pair of film panels positioned face to face and having first and second lengthwise edges, and first and second foam dispensing assemblies positioned to dispense foam between the film panels, each foam dispensing assembly comprising first and second valves that dispense first and second foam components, respectively, the valves positioned so that respective foam component streams exiting the valves intersect.

Abstract: A machine for forming foam cushions comprises a web of film comprising a pair of film panels positioned face to face and having first and second lengthwise edges, and first and second foam dispensing assemblies positioned to dispense foam between the film panels, each foam dispensing assembly comprising first and second valves that dispense first and second foam components, respectively, the valves positioned so that respective foam component streams exiting the valves intersect.

Abstract: A composite air and foam protective packaging product comprises a packaging cushion having, in cross-section, at least three plies of plastic film, foam between a first ply and a second ply of the three plies of plastic film, and air between the second ply and a third ply of the three plies of plastic film.

Abstract: A composite air and foam protective packaging product comprises a packaging cushion having, in cross-section, at least three plies of plastic film, foam between a first ply and a second ply of the three plies of plastic film, and air between the second ply and a third ply of the three plies of plastic film.

Abstract: A composite air and foam protective packaging product comprises a packaging cushion having, in cross-section, at least three plies of plastic film, foam between a first ply and a second ply of the three plies of plastic film, and air between the second ply and a third ply of the three plies of plastic film.

Abstract: A machine for forming foam cushions comprises a web of film comprising a pair of film panels positioned face to face and having first and second lengthwise edges, and first and second foam dispensing assemblies positioned to dispense foam between the film panels, each foam dispensing assembly comprising first and second valves that dispense first and second foam components, respectively, the valves positioned so that respective foam component streams exiting the valves intersect.

Abstract: A cushioning dunnage producing machine comprises a crumpler, a roll of paper sheet material having a first end at a radially innermost location and a second end at a radially outermost location, the first end fed into the crumpler, the crumpler drawing the paper sheet from the roll and crumpling the paper sheet into cushioning dunnage, and a cutter which travels laterally across the cushioning dunnage to cut the dunnage into a strip of a desired length.

Abstract: A composite air and foam protective packaging product comprises a packaging cushion having, in cross-section, at least three plies of plastic film, foam between a first ply and a second ply of the three plies of plastic film, and air between the second ply and a third ply of the three plies of plastic film.

Abstract: Apparatus for producing and separating a string of interconnected packing cushions comprises a packing cushion production machine which produces a string of interconnected packing cushions, the string of interconnected packing cushions exiting an output end of the machine at a first velocity, and a separation device associated with the output end of the machine, the separation device adapted to selectively engage the string of interconnected packing cushions and to drive the string at a second velocity, greater than the first velocity, and in doing so to cause the string of interconnected packing cushions to separate.

Abstract: A method of automating a packaging system comprises receiving from a customer an order to be shipped to the customer, determining a volume of the order, selecting a box having a volume sufficient to contain the order and a desired quantity of cushioning product, determining a difference in the volumes of the box and the order, generating a signal based on the difference in the volumes, and causing, with the signal, a cushioning product producing and/or dispensing machine to produce and/or dispense the desired quantity of cushioning product.

Abstract: Apparatus for producing and separating a string of interconnected packing cushions comprises a packing cushion production machine which produces a string of interconnected packing cushions, the string of interconnected packing cushions exiting an output end of the machine at a first velocity, and a separation device associated with the output end of the machine, the separation device adapted to selectively engage the string of interconnected packing cushions and to drive the string at a second velocity, greater than the first velocity, and in doing so to cause the string of interconnected packing cushions to separate.

Abstract: Apparatus for handling loosefill and conveying the loosefill from one location to another comprises a container having a bottom and sides, the container being adapted to receive and contain therein a quantify of loosefill, a blower positioned at one end of the container, and conduit which channels air from the blower toward the other end of the container and which redirects the air back toward the one end of the container to thereby convey therewith the loosefill. A vacuum is positioned at the one end of the container which draws the loosefill out of the container. The container may be a trailer of a tractor trailer. A method of conveying loosefill from one location to another comprises providing a container of loosefill, providing an air source at one end of the container, directing air from the air source toward the other end of the container, and redirecting the air back towards the one end of the container to thereby convey therewith the loosefill to the one end of the container.

Abstract: A cushioning product comprises an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along the fold lines in an accordion-like fashion, and a storage and dispensing device which stores the folded sheet compressed and from which the sheet is dispensed for use. The sheet can be 8″ to 12″ wide. The fold lines can be 1″ apart. The sheet can have transverse perforations. The transverse perforations can be 16″ apart. The sheet has lateral edge portions and the lateral edge portions can be folded over onto the balance of the sheet. The folded over lateral edge portions can be 2″ wide, or the folded over lateral edge portions can substantially meet. In the latter case the folded over lateral edge portions can have a small space between them. The paper stock can be Kraft paper, recycled paper, or a combination of Kraft paper and recycled paper.

Abstract: Apparatus for handling loosefill and conveying the loosefill from one location to another comprises a container having a bottom and sides, the container being adapted to receive and contain therein a quantify of loosefill, a blower positioned at one end of the container and conduit which channels air from the blower toward the other end of the container, and which redirects the air back toward the one end of the container to thereby convey therewith the loosefill. A vacuum is positioned at the one end of the container which draws the loosefill out of the container. The container may be a trailer of a tractor trailer. A method of conveying loosefill from one location to another comprises providing a container of loosefill, providing an air source at one end of the container, directing air from the air source toward the other end of the container, and redirecting the air back towards the one end of the container to thereby convey therewith the loosefill to the one end of the container.

Abstract: Apparatus for producing and conveying air pillows comprises an air pillow production machine which produces a continuous web of air filled pillows, ductwork extending away from the air pillow production machine and through which the web of air pillows is conveyed, and a blower which conveys the web of air pillows from the air pillow production machine and through the ductwork. The web of air pillows are conveyed into a hopper for storage. A sensor senses a condition of at least one of the air pillows in the web of air pillows being deflated or a stall condition of the web of air pillows in the event the web of air pillows stops moving through the ductwork. A controller controls the air pillow production machine in response to signals from the sensor. The sensor and controller are a whisker trigger connected to a micro switch.

Abstract: Apparatus for handling loosefill and conveying the loosefill from one location to another comprises a container having a bottom and sides, the container being adapted to receive and contain therein a quantify of loosefill, a blower positioned at one end of the container, and conduit which channels air from the blower toward the other end of the container and which redirects the air back toward the one end of the container to thereby convey therewith the loosefill. A vacuum is positioned at the one end of the container which draws the loosefill out of the container. The container may be a trailer of a tractor trailer. A method of conveying loosefill from one location to another comprises providing a container of loosefill, providing an air source at one end of the container, directing air from the air source toward the other end of the container, and redirecting the air back towards the one end of the container to thereby convey therewith the loosefill to the one end of the container.