Disclosed herein are protective packaging stock material units that are used in a dunnage system. A dunnage system includes a dunnage conversion machine and a supply station. The supply station is a cart that includes a biased support that is connected to a vertical side support. The biased support is movable from an open position to a closed position with respect to opposing vertical side supports. In the closed position, the biased support is configured to at least partially block the opening between the opposing vertical side supports. In the open position, the biased support leaves the opening between the opposing vertical side supports sufficiently open to load fanfold stock material therein. The biased support is biased towards the closed position and the open position. The supply station also includes an alignment device forming a funnel positioned under its base. The alignment device receives a dunnage machine stand base causing the supply cart to consistently align with the stand base in response to the stand base being slid into engagement with the alignment device.

A dunnage system may include a converting station including a converter configured for pulling in a stream of sheet material and converting the material into dunnage, and an inlet guide having an inlet surface that is coiled such that first and second ends of the inlet surface are discontinuous with each other to define a gap therebetween, the inlet surface configured to channel the sheet material into the converter. A cutter for a dunnage system may include a blade with first and second phases of serrations that are coextensive over at least a portion of the blade, the first phase providing cutting serrations for cutting the dunnage, and the second phase comprising ledges for focusing the cutting and preventing or reducing bunching of the dunnage towards a side of the blade. A method of converting dunnage may also be provided.

A dunnage system may include a converting station including a converter configured for pulling in a stream of sheet material and converting the material into dunnage, and an inlet guide having an inlet surface that is coiled such that first and second ends of the inlet surface are discontinuous with each other to define a gap therebetween, the inlet surface configured to channel the sheet material into the converter. A cutter for a dunnage system may include a blade with first and second phases of serrations that are coextensive over at least a portion of the blade, the first phase providing cutting serrations for cutting the dunnage, and the second phase comprising ledges for focusing the cutting and preventing or reducing bunching of the dunnage towards a side of the blade. A method of converting dunnage may also be provided.

A supply of stock material for a dunnage conversion machine includes two plies of sheet stock material wound into a roll or fan-folded into a stack. Each ply has disposed on a corresponding leading or trailing end thereof an adhesive layer and a removable release liner covering the adhesive layer. When applied to a leading end of the supply, the adhesive layer is applied to opposing, outwardly-facing surfaces of the respective plies. When a supply of stock material is almost spent, the operator removes the release liners from both plies to expose respective adhesive layers, and then interposes the leading end of a new supply between the plies of the trailing end of the almost-spent supply and presses the layers together to attach the plies of the new supply to respective plies of the almost-spent supply, for conversion into dunnage.

A dunnage production system for producing coiled strips of dunnage includes a supply of strip-like dunnage, a coiler adjacent the supply and rotatable about a coiling axis for coiling a strip of the strip-like dunnage into a coil having a coiled configuration, and a tube aligned with the coiling axis. The tube has an internal diameter sized to receive the coil from the coiler in a discharge direction parallel to the coiling axis. The tube is capable of holding at least one coil in its coiled configuration until it is removed from the tube.

A dunnage system may include a converting station including a converter configured for pulling in a stream of sheet material and converting the material into dunnage, and an inlet guide having an inlet surface that is coiled such that first and second ends of the inlet surface are discontinuous with each other to define a gap therebetween, the inlet surface configured to channel the sheet material into the converter. A cutter for a dunnage system may include a blade with first and second phases of serrations that are coextensive over at least a portion of the blade, the first phase providing cutting serrations for cutting the dunnage, and the second phase comprising ledges for focusing the cutting and preventing or reducing bunching of the dunnage towards a side of the blade. A method of converting dunnage may also be provided.

Methods and structures are provided for a dunnage system to facilitate efficient coupling together of supply units of pre-configured sheet stock material, such as, for example, separate units of fanfold stacks of pre-configured sheet stock material, in a manner of continuous supply with a continuous pocket extending longitudinally between the separate supply units, so that they can interact with an expander of the dunnage system without disruption as one supply unit is depleted and a next supply unit is fed through the dunnage system. Also, various methods, apparatus, and systems are provided to facilitate smooth operation of a dunnage machine of the dunnage system to reduce a tendency of the pre-configured sheet stock material to jam and to increase the tendency of dunnage product generated to reflect a desired shape and stability.

A dunnage conversion assembly includes a supply of expandable sheet material and a dunnage conversion apparatus configured to expand the expandable sheet material. The apparatus includes a frame, a supply support mounted to the frame to support a supply of sheet material, and first and second expansion members rotatably mounted to the frame downstream of the supply support to receive the sheet material therebetween. At least one of the first expansion member or the second expansion member is rotatably driven. A drive assembly of the apparatus includes a drive member and a motive device that drives rotation of the drive member to dispense the sheet material from the supply. The drive member is movable between an operating position adjacent the supply support and a disengaged position spaced from the supply support. The drive member in the operating position is biased toward the supply support.

A material dispenser having a dispensing member configured to dispense a line of the material along a path in a downstream direction, and a cutting member having a cutting edge extending generally downstream with respect to the path. The cutting member having a convex shape across the path, such that the cutting edge engages and sequentially initiates cuts through the line of material when the line of material is pulled against the cutting member, thereby minimize cutting forces.

An apparatus for supplying a coil-like padding product for packaging purposes comprises a supply device for supplying a web-type padding material and also a rolling-up apparatus, which rolls up the web-type padding material to form the coil-like padding product. It is proposed that the rolling-up apparatus should comprise a flexible delimiting means, which can form an at least partially curved delimiting wall of an at least temporarily present rolling-up space, of which the extent is preferably alterable and which has an inlet for the web-type padding material, it being possible for the web-type padding material to enter into the rolling-up space through said inlet, wherein the web-type padding material is guided by the at least partially curved delimiting wall, this resulting in the formation of the coil-like padding product.