The invention relates to a method for producing a cushioning product (88), comprising the following steps: providing a flat, longitudinal, two- or multilayered paper strip (10), wherein the individual layers (12, 14) of the paper strip (10) are connected to one another in at least some sections in a middle area (18) extending in the longitudinal direction, and wherein the individual layers (12, 14) of the paper strip (10) comprise marginal areas (20, 21, 22, 23) which are not connected to one another, opening adjacent marginal areas (20, 21, 22, 23) to form a paper strip (10) having a star-shaped cross section, and crumpling the paper strip (10) along the middle area (18).

The invention relates to a method for producing a cushioning product (88), comprising the following steps: providing a flat, longitudinal, two- or multilayered paper strip (10), wherein the individual layers (12, 14) of the paper strip (10) are connected to one another in at least some sections in a middle area (18) extending in the longitudinal direction, and wherein the individual layers (12, 14) of the paper strip (10) comprise marginal areas (20, 21, 22, 23) which are not connected to one another, opening adjacent marginal areas (20, 21, 22, 23) to form a paper strip (10) having a star-shaped cross section, and crumpling the paper strip (10) along the middle area (18).

A foldable container blank includes at four side walls, a top panel foldably connected to one of the side walls, a bottom panel foldably connected to one of the side walls, and at least one internal support structure that is connected to one of the side walls. Each internal support structure includes a first portion that is in adjacent relation with the top panel when the container is in a closed condition, and a second portion that is in adjacent relation with the first portion when the container is in a closed condition. In some embodiments, the foldable container blank is integrally formed. A method of forming the foldable container blank and a method of folding a container blank are also provided.

A product packaging system in one embodiment includes a stack of products defining a pair of opposing major side surfaces, a top surface, a bottom surface, and pair of opposing end surfaces; protective corrugated sheets covering two or more of the stack side, top, and bottom surfaces; and a protective end pad covering each of the stack end surfaces. Each protective corrugated sheet includes a pair of longitudinally-extending and protruding corner reinforcement structures disposed along corner regions of the stack. The reinforcement structures are three-dimensional structures having different possible configurations which provide crush-resistance in the assembled product package. The product package collectively comprising the foregoing components is insertable into an outer shipping carton for transit. Some embodiments include banding which holds the stack of products together. In one embodiment, the products may be mirrors.

An apparatus and method for manufacturing a notched corner board is disclosed. The method includes cutting bent board stock into fixed lengths; forming a slit in or near an end of the corner board; and bending/folding a part of the corner board between the end and the slit to create a notch or flap in the corner board. The apparatus includes one or more cutting tools configured to form a slit in or near a first end of the corner board, a support block configured to support the corner board as the slit is formed, one or more rollers configured to move the corner board towards the cutting tool(s), a frame to which the cutting tool(s), the support block, and the roller(s) are directly or indirectly attached, a motor, and a punch. The motor controls movement of the punch to form the notch in the corner board.

A shipping system for shipping planar substrates includes a plurality of planar substrates stacked to form a pack and a plurality of interleaving material including substantially spherical beads positioned between the substrates of the pack and configured to carry a load. Substantially all of the beads have a diameter within 25% of D.sub.max, where D.sub.max is a diameter corresponding to a size of an opening of an upper limit sieve used in the shipping system. Also disclosed are a spacer for use in a shipping system for shipping planar substrates, a wrapped system for shipping planar substrates, a method of wrapping a system for shipping planar substrates, and a powder applicator.

A shipping system for shipping planar substrates includes a plurality of planar substrates stacked to form a pack and a plurality of interleaving material including substantially spherical beads positioned between the substrates of the pack and configured to carry a load. Substantially all of the beads have a diameter within 25% of D.sub.max, where D.sub.max is a diameter corresponding to a size of an opening of an upper limit sieve used in the shipping system. Also disclosed are a spacer for use in a shipping system for shipping planar substrates, a wrapped system for shipping planar substrates, a method of wrapping a system for shipping planar substrates, and a powder applicator.

Packaging may include cushioning elements. Molded fiber cushioning elements may be configured as end caps, and may include independently flexible panels. The cushioning elements may include an upper and lower panel fixed together about their periphery, but free to bend and translate about and along each other otherwise. The cushioning elements may include opposed mechanical bends that are proximate a friction interface, thereby allowing the cushioning element to absorb impact and vibration, and replacing the need for less environmentally friendly cushioning, such as expanded polystyrene or foam cushioning.

Wrapped paperboard packaging is described. In one independent aspect, a packaging structure, such as, for example, an edge protector, a corner board, etc., may generally include a first ply having a first width, a second ply having a second width wider than the first width, and a third ply having a third width wider than the second width. The second ply is wrapped around ends of the first ply, and the third ply is wrapped around the first ply and the second ply. The third ply overlaps at a portion (e.g., an intermediate portion, an apex, etc.) of the packaging structure.

A buffer material includes a pair of impact absorption parts. Each of the pair of impact absorption parts has a first rectangular plate part, which is formed by cutting a predetermined place of the sheet material and is bendable downward along one end edge, and a second rectangular plate part which is concatenated to the other end edge of the first rectangular plate part and has a length in a direction along the other end edge, which is longer than a length in the direction of the first rectangular plate part. Each of the pair of impact absorption parts is formed by bending the first rectangular plate part in a sectional V shape and allowing both end portions of the second rectangular plate part in the direction along the other end edge to be engaged with and held to an upper surface of the support plate part.