An insulating shipping container includes an exterior box formed of paper defining a cavity and an interior box formed of paper and positioned within said cavity. The interior box defines a product cavity. A compressed mass of compostable insulating plant material of pellet/granular form is received in the cavity and around the interior box. The compressed mass of compostable insulating plant material has a compression ratio of at least 1.25:1 in comparison to a free-flowing loose-filled condition of the pellet/granular form sufficient to provide the compressed mass of compostable insulating plant material with a thermal insulating value (R value) substantially equal to or better than EPS.

An insulating shipping container includes an exterior box formed of paper defining a cavity and an interior box formed of paper and positioned within said cavity. The interior box defines a product cavity. A compressed mass of compostable insulating plant material of pellet/granular form is received in the cavity and around the interior box. The compressed mass of compostable insulating plant material has a compression ratio of at least 1.25:1 in comparison to a free-flowing loose-filled condition of the pellet/granular form sufficient to provide the compressed mass of compostable insulating plant material with a thermal insulating value (R value) substantially equal to or better than EPS.

A system, method and apparatus for forming a flex-column includes a three-sided column having a triangular cross-sectional shape, an open first end, an open second end, and three corners, each one of the three sides including a flex line dividing each of the three sides into two portions, at least one perforation along an edge of each one of the two portions wherein the edge of each one of the two portions coincides with one of the three corners and at least one non-perforation along an edge of each one of the two portions.

A system, method and apparatus for forming a flex-column includes a three-sided column having a triangular cross-sectional shape, an open first end, an open second end, and three corners, each one of the three sides including a flex line dividing each of the three sides into two portions, at least one perforation along an edge of each one of the two portions wherein the edge of each one of the two portions coincides with one of the three corners and at least one non-perforation along an edge of each one of the two portions.

An improved insulated shipping container including an external or outer corrugated cardboard box, receiving an inner product box centrally disposed therein. Between the inner and outer cardboard boxes are plural strata or layers of insulating pellets compressed or compacted to a selected degree. Compression of the insulating pellets both interlocks these insulating pellets so as to prevent their migration during transit of the shipping container, and substantially reduces the interstitial space or volume that would otherwise exist among the pellets. The bulk insulating value of the pellets is significantly improved. The entire container is biodegradable, and may be composted.

An improved insulated shipping container including an external or outer corrugated cardboard box, receiving an inner product box centrally disposed therein. Between the inner and outer cardboard boxes are plural strata or layers of insulating pellets compressed or compacted to a selected degree. Compression of the insulating pellets both interlocks these insulating pellets so as to prevent their migration during transit of the shipping container, and substantially reduces the interstitial space or volume that would otherwise exist among the pellets. The bulk insulating value of the pellets is significantly improved. The entire container is biodegradable, and may be composted.

Thermally-stabilizing pellets are used in a contents container to stabilize the temperature at which temperature sensitive contents are stored in the container. The pellets provide a thermal buffer between the stored contents and the environment outside the contents container that retards the rate of temperature change of the stored contents. The stored contents do not experience the extremes in temperature variation within a passive or active thermally insulated container when at least partially buried in the pellets. The pellets can also help isolate the stored contents from phase change materials that could thermally damage the stored contents with physical contact.

Thermally-stabilizing pellets are used in a contents container to stabilize the temperature at which temperature sensitive contents are stored in the container. The pellets provide a thermal buffer between the stored contents and the environment outside the contents container that retards the rate of temperature change of the stored contents. The stored contents do not experience the extremes in temperature variation within a passive or active thermally insulated container when at least partially buried in the pellets. The pellets can also help isolate the stored contents from phase change materials that could thermally damage the stored contents with physical contact.

A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. In a first step, dense pellets or granules are formed from starch and a plasticizing agent such as polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs./cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water and using a dwell time. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.

A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. In a first step, dense pellets or granules are formed from starch and a plasticizing agent such as polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs./cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water and using a dwell time. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.