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 method that includes the steps of (i) attaching a leading portion of a supply of stock material to a trailing portion of a preceding supply of stock material by means of a mechanical fastener, an electromagnetic field, electrostatic charges, or an activatable bonding agent, and (ii) converting the stock material into a relatively less dense dunnage product. The attaching step may include (a) embossing, punching, stitching, stapling, riveting, clipping, snapping, buttoning, attaching with male and female interlocking devices or hook-and-loop fasteners, (b) integrating one or more elements into the stock material to provide a stock material with magnetic or magnetizable material in the leading or trailing portion, (c) imparting opposing and attractive magnetic charges in respective leading and trailing portions, (d) inducing an electrostatic charge or a magnetic field in at least one of the leading and trailing portions, and/or (e) activating a bonding agent.

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: An automated packaging system has a plurality of dunnage dispensing stations that can dispense dunnage and a transport network for conveying containers to and from at least two dispensing stations for dunnage to be placed therein. At at one loading station upstream of a dispensing station articles are placed in the containers for shipping. Optionally, an intermediate void determination station determines how much dunnage to dispense.