Queue-based bag forming system and method

A system for forming a series of bags of varying desired characteristics and dimensions for containing a like number of bulky articles each requiring a bag of said varied characteristics and dimensions, comprising:

• a pair of thermoplastic film rolls selectively driveable together each to feed a layer of a thermoplastic film;
• a padding element roll selectively driveable to feed a layer of a padding element interbetween the layers of thermoplastic film to form a sandwich;
• means for cutting the padding element to form a window in one of the bags;
• means for folding the sandwich to form an envelope;
• a seal-cutter for forming a seal-cut whereby a trailing end of a first bag and a leading end of a second bag are sealed and at least partially cut, wherein the seal-cutter comprises an anvil and a sealer bar comprising a sealing surface having a central ridge for increasing clamping pressure along a cut line, the sealer bar being selectively heatable to a desired temperature and the sealer bar and the anvil cooperating to apply even pressure to the envelope;
• a clamping profile wider than the sealing surface of the sealer bar for applying a selected clamping pressure across the clamping profile to clamp the layers of the film envelope between the sealer bar and the anvil;
• and
• a microprocessor control for controlling operation of the means for cutting, operation of the seal-cutter, and coordinated movement of a queue comprising the layers of film and the layer of padding element, according to the varying desired characteristics and dimensions of the bags.