Abstract: Fiber-based composite material for use in an automated packaging formation and padded mailers and corresponding systems and methods are provided herein. A fiber-based composite includes a fiber-based liner defining a liner width and a fiber-based padding defining a first surface and a second surface attached to the backing material to provide cushioning for items within a mailer. The fiber-based padding defines a padding width which is less than the liner width thereby defining a first liner overhang and a second liner overhang. A heat seal material is disposed on the first surface of the fiber-based padding, the first liner overhang and the second liner overhang to aid in heat seal formation between opposite surfaces when used to form a package. The heat seal material may, in some cases, includes an anti-stick additive.

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. The padded material defines a plurality of consecutive panel sections formed of a first edge, a second edge, a first panel breakline and a second panel breakline. A first adhesive is positioned between corresponding portions of the first web and the second web. A starch-based padding is sandwiched between the first web and the second web with a second adhesive. The starch-based padding defines a non-uniform placement density along the first web between 15%-40%. The placement density is the ratio of area covered by the starch-based particles to the web area defined between the first edge, second edge, first panel breakline, and second panel breakline.

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.