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.

A method for producing a multi-layer foam sheet having a foam layer and a resin layer laminated on at least one side of the foam layer, includes coextruding a foamable molten resin composition which contains a low density polyethylene and a physical blowing agent and a molten resin composition which contains 80 to 20% by weight of a specific ethylene-propylene random copolymer and 20 to 80% by weight of a specific polyethylene resin so that the foamable molten resin composition forms the foam layer and the molten resin composition forms the resin layer.

A multi-layer foam sheet with an apparent density of 30 to 300 kg/m.sup.3 and a thickness of 0.05 to 2 mm, including a foam layer containing a polyethylene-based resin (A), and an antistatic layer fusion-laminated by coextrusion on each of both sides of the foam layer. The antistatic layer has a basis weight of 1 to 10 g/m.sup.2 and contains a polyethylene-based resin (B), a polystyrene-based resin, a styrenic elastomer, and a polymeric antistatic agent, with the polystyrene-based resin being contained in the antistatic layer in an amount of 15 to 70% by weight.

According to some illustrative embodiments, a protective product is provided that includes: at least one expandable slit paper sheet, said at least on expandable slit paper being expanded between opposing ends of said slit paper; a first embossed paper sheet facing said expanded slit paper sheet and a second paper sheet facing an opposite side of said at least one expanded slit paper sheet, at least one of said first embossed paper sheet and said second paper sheet being fixed to said expanded slit paper sheet at the opposing ends of said expanded slit paper sheet and thereby maintaining said expanded paper in its expanded state, said first embossed paper sheet having a plurality of embossings that increase the rigidity of said embossed paper sheet, whereby inhibiting deformation of said embossed paper sheet that is fixed to said expanded slit sheet paper.

A molded packing material and a method of making the molded packing material. The molded packing material includes a plurality of molded fiber cushioning elements. The molded packing may also include a matrix comprising cellulosic fibers bonding the plurality of molded fiber cushioning elements to each other. The plurality of molded fiber cushioning elements and matrix form a mass that has been molded into a shape having exterior surfaces and an interior with some of the plurality of molded fiber cushioning elements being on the exterior surfaces of the mass and the remainder of the plurality of molded fiber cushioning elements being in the interior of the mass. The molded packing material may also include a fiber shell having a cavity formed therein with the plurality of molded fiber cushioning elements located in the cavity.

There is provided a technology capable of controlling the occurrence of migration of a foam material to a contact object.

The present technology provides a package material containing: a fibrous material that includes waste paper and/or pulp; a binder; sodium hydrogen carbonate; a surfactant; and a water-soluble softener, the water-soluble softener being a urea derivative having a chemical structural formula of R.sup.1,R.sup.2NCONR.sup.3,R.sup.4 (R.sup.1 to R.sup.4 are each H or a saturated and/or unsaturated hydrocarbon group having 1 to 4 carbon atoms) and/or a water-soluble polyhydric alcohol having 3 to 15 carbon atoms, the number of carbon atoms and the number of hydroxyl (OH) groups in a molecular structure of the water-soluble polyhydric alcohol satisfying a relationship of the number of hydroxy groups<the number of carbon atoms.

A stock of a protective packaging material comprises foamed polysaccharide material. It is suggested that the stock comprises a plurality of essentially and generally flat panels each having at least a straight side edge, wherein adjacent panels are connected to each other at their common straight side edges by means of a hinge portion and are folded relative to each other such that they form a stack of essentially parallel panels.

The present invention relates to a method for producing a multi-layer substrate, said substrate comprising a multifunctional coating, and to the use of the substrate produced by this method.

The present invention relates generally to a protective wrap and a protective envelope or pouch made therefrom, as well as the apparatus and process for forming such wraps and envelopes. Water-based heat-expandable adhesives (WBHEA) which include a plurality of heat-expandable microspheres are disposed in a pattern between web substrates on a continuous, high speed manufacturing line to produce padded, insulated products useful as envelopes, mailers and other protective packaging.

The presently disclosed subject matter generally relates to recyclable insulation material for shipping containers, groceries bags, etc., machines for making the recyclable insulation material, and methods for the making the recyclable insulation material. In one aspect, an insulation product may include a first layer and a first continuous paper sheet formed into a first plurality of flexible loops disposed on and attached to the first layer and defining a first plurality of air channels that extend in a direction that is substantially perpendicular with a machine direction of the insulation product. A take up factor of the first continuous paper sheet to the first layer may be greater than 1:1.