An elongate flattened thermoplastic tube has an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of weakness that allow adjacent dunnage units to be separated. A frangible line of connection is disposed in one two superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.

A system includes a source of sheet material and a conversion machine. The conversion machine is configured to receive the sheet material and to form the sheet material into a fill material. The conversion machine further includes a cutting system configured to selectively cut the fill material either partially or completely to form two pieces of the fill material. When the cutting system partially cuts the fill material, uncut portions of the fill material remain between the two pieces of the fill material. When the cutting system completely cuts the fill material, no uncut portions remain between the two pieces of the fill material.

A system includes a source of sheet material and a conversion machine. The conversion machine is configured to receive the sheet material and to form the sheet material into a fill material. The conversion machine further includes a cutting system configured to selectively cut the fill material either partially or completely to form two pieces of the fill material. When the cutting system partially cuts the fill material, uncut portions of the fill material remain between the two pieces of the fill material. When the cutting system completely cuts the fill material, no uncut portions remain between the two pieces of the fill material.

An inflatable web is disclosed. The web includes a first film and second film ply sealed together via a plurality of generally transverse seals. The transverse seals define first and second inflatable chambers. The inflatable chambers are inflatable with, and contain, a fluid. The web defines a separation region extending at least partially between the first and second inflatable chambers in a substantially transverse direction across the web and configured to facilitate separation of the first and second inflatable chambers. The separation region includes a tear initiation feature that facilitates tearing of the web to separate the first and second inflatable chambers. The separation region includes a tear propagation line at least partially longitudinally offset from the tear initiation feature, and close enough to the tear initiation feature that force imparted to the web via the tear initiation feature will tear of the web through the tear propagation line.