Foldable packaging insert comprising multiple cellulose-based air-laid or solid foam substrates

A method for producing a packaging insert comprising:

• cutting a cellulose-based air-laid or solid foam substrate blank at a first angle (β) of less than 45° relative to a normal of a main side of the cellulose-based air-laid or solid foam substrate blank and at a second angle (β) equal to but of opposite sign to the first angle (β) to obtain a first cellulose-based air-laid or solid foam substrate comprising a beveled edge a second cellulose-based air-laid or solid foam substrate comprising two beveled edges and a third cellulose-based air-laid or solid foam substrate comprising a beveled edge;
• turning the second cellulose-based air-laid or solid foam substrate upside down so that the beveled edge of the first cellulose-based air-laid or solid foam substrate faces a first beveled edge of the second cellulose-based air-laid or solid foam substrate and the beveled edge of the third cellulose-based air-laid or solid foam substrate faces a second beveled edge of the second cellulose-based air-laid or solid foam substrate, wherein
• the beveled edge of the first cellulose-based air-laid or solid foam substrate and the first beveled edge of the second cellulose-based air-laid or solid foam substrate form an angle (α) between the beveled edges that is less than 90°;
• and
• the beveled edge of the third cellulose-based air-laid or solid foam substrate and the second beveled edge of the second cellulose-based air-laid or solid foam substrate form an angle (α) between the beveled edges that is less than 90°;
• and
• attaching a first paper-based sheet to first main sides of the first cellulose-based air-laid or solid foam substrate, the second cellulose-based air-laid or solid foam substrate, and the third cellulose-based air-laid or solid foam substrates and a second paper-based sheet to second main sides of the first cellulose-based air-laid or solid foam substrate, the second cellulose-based air-laid or solid foam substrate, and the third cellulose-based air-laid or solid foam substrates to form a packaging insert comprising:
• a first hinge section interposed between the beveled edge of the first cellulose-based air-laid or solid foam substrate and the first beveled edge of the second cellulose-based air-laid or solid foam substrate;
• and
• a second hinge section interposed between the second beveled edge of the second cellulose-based air-laid or solid foam substrate and the beveled edge of the third cellulose-based air-laid or solid foam substrate.