Starch-based padded material, padded mailers and methods of making the same

Abstract

Padded materials and corresponding systems and methods for forming the same are provided herein. A padded material comprises a first web of paper-based material defining a first and a second surface, and a second web of paper-based material defining a first and a second surface. The padded material defines a plurality of consecutive panel sections formed of a first edge, a second edge, a first panel breakline and a second panel breakline. A first adhesive is positioned between corresponding portions of the first web and the second web. A starch-based padding is sandwiched between the first web and the second web with a second adhesive. The starch-based padding defines a non-uniform placement density along the first web between 15%-40%. The placement density is the ratio of area covered by the starch-based particles to the web area defined between the first edge, second edge, first panel breakline, and second panel breakline.