A packaging material web stock is provided. The packaging material web stock can include first and second plies overlaid and sealed to each other at a plurality of seals that include a plurality of transverse seals extending transversely across the plies, wherein a plurality of interior cavities are defined between the plies and the transverse seals, the first and second plies arranged in a web that includes a plurality of packaging units arranged longitudinally in a series along the web, wherein the first and second plies form walls of the packaging units, and at least some of the packaging units include at least one of the interior cavities, and an expansion material disposed in the interior cavities in an unexpanded configuration, wherein the expansion material is arranged within the inner cavities such that, when expanded to the expanded configuration, the expansion material is configured to provide cushioning in the walls.

A machine and method for making bags is described and includes a web traveling from an input section to a rotary drum, to an output section. The rotary drum includes at least one seal bar, having a single sealing zone, and a weakening zone disposed within the single sealing zone. The single sealing zone may be a heated perforator, includes a heating wire. The heating wire may be an NiCr wire stitched into the heater, and be disposed on a cap or on the seal bar. The weakening zone may create a line of weakness that is uniform or varies in intensity. The sealing zone may include temperature zones, cartridge heaters, cooling air, or heated air, or a source of ultrasonic, microwave or radiative energy.

A machine and method for making bags is described and includes a web, traveling from an input section to a rotary drum, to an output section. The rotary drum includes at least one seal bar, having a first sealing zone, and an adjacent weakening zone. The weakening zone may be a heated perforator, includes a heating wire, or be disposed to create an auxiliary sealed area. The heating wire can have, connected thereto, a source of power that is at an adjustable voltage or magnitude, and/or pulsed, and/or a feedback loop. The heating wire may be an NiCr wire and make intermittent contact with the web and be disposed in an insert. The weakening zone may create a line of weakness that is uniform or varies in intensity, is a separating zone, or includes a heat film, a toothed blade, a row of pins, a source of air, or a source of vacuum. The sealing zones may include temperature zones, cartridge heaters, cooling air, or heated air, or a source of ultrasonic, microwave or radiative energy.

A bagger device is provided. The bagger device can include a bag handler configured to handle packaging material configured to define a bag that has first and second walls enclosing an interior cavity configured to contain an object therein for shipping, the first wall including an expansion material that has an expandable configuration and that is expandable to an expanded configuration for providing padding to the first wall to protect the object contained within the interior cavity. The bagger device can further include an expansion device configured to apply expanding conditions to the packaging material, the expanding conditions configured to cause the expandable material to expand from the expandable configuration to the expanded configuration.

A thermoplastic bag includes duplicative seals. In particular, in one or more implementations, a thermoplastic bag includes a first seal and at least a second seal reinforcing the same area of the thermoplastic bag. For instance, in one or more implementations, the thermoplastic bag includes multiple seals along each side edge or along the hem. If one seal fails, the other seal(s) can remain in place to prevent leaks. Thus, the duplicative seals of the thermoplastic bag can provide reinforced strength and desired aesthetics.