Abstract: Padded materials and corresponding systems and methods for forming the same are provided herein. A padded material comprises a first web of paper-based material defining a first and a second surface, and a second web of paper-based material defining a first and a second surface. A first layer of heat seal coating is disposed on the second surface of the first web, and a second layer of heat seal coating is disposed on the second surface of the second web. A starch-based padding is sandwiched between the first web and the second web such that the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web. The padded material may be formed into a roll stock that is used in an automated packaging machine, such as an automated mailer formation device.

Abstract: Systems for applying low viscosity print coating to a web product using a coating roller and an off-press system are provided herein. An example system includes an unwinding station and a winding station. A motor causes the web product to travel along a web path. A coating roller applies a low viscosity print coating to a first side of the web product at a first position along the web path. The low viscosity print coating comprises a salt solution with a centipoise that is less than or equal to 100 centipoise that is configured to enhance printability. A backing roller applies a backing coating to a second, opposite side of the web product at a second, different position along the web path. The backing coating enhances sheet stability of the web product. A drying station dries the low viscosity print coating and the backing coating to remove moisture.