Abstract: An improved apparatus and method for producing fully air-cushioning dunnage from two sources of flexible thermoplastic film. This improved apparatus and method provides a fully air-filled dunnage by maintaining a forming roller (16) at a cold temperature. The outer surface (33) has a thermo-resistive layer (32) completely convering its periphery absent a plurality of cavities (30) formed therein. A first film (12) is heated then thermoformed into said cavities (30). The thermoformed portions of the film contact the cold cavities in the forming roller to cool both the film and the air in the cavities to a cold temperature. The heat welding surface of first film (12) is kept at an elevated temperature by the thermo-resisitive layer. A second film (20) is heated and welded to said first film by and with an adjustable heated pressure roller (24). The heat traveling through the second film and the first film is delayed for a predetermined amount of time by the thermo-resistive layer.