On-demand inflatable packaging

A method for converting a web of preformed plastic pouches to on-demand inflatable packaging, the plastic pouches being defined by side edges, two panels, and at least one panel having an inflation pattern, the inflation pattern of each of the plastic pouches is uninflated such that the web is in a non-inflated state, the web having a continuous inflation channel that is in fluid communication with the inflation pattern of each of the plastic pouches, the method comprising:

• moving the web along a path of travel;
• attaching a plastic outer skin to an outside of the web when the web is in the non-inflated state such that each of the preformed pouches of the web is configured to be inflated by inflating the inflation pattern of the preformed pouches with the plastic outer skin already attached to the outside of the web, wherein a first layer of the plastic outer skin is attached to a first panel of the two panels of the preformed pouches and a second layer of the plastic outer skin is attached to a second panel of the two panels of the preformed pouches, wherein the plastic outer skin is only attached to the web along edge lines of the preformed pouches and the plastic outer skin is detached from the web between the edge lines of the preformed pouches, and wherein the plastic outer skin is attached to the outside of the web such that the continuous inflation channel extends above the plastic outer skin;
• packaging the web into a stored configuration when the web is in the non-inflated state and after the plastic outer skin is attached to the web.