Types of Insulation Packaging and How They Work

We live in a global market, where shoppers can buy all kinds of goods from just about anywhere in the world and sales aren’t limited by location. Many industries ship products across the country and around the world every day, including goods that require a temperature-controlled environment to maintain freshness and safety.

So, how do companies keep these goods from spoiling? With thermal insulation packaging—the primary component to cold chain shipping. In this article, we’ll talk about the various types of insulation packaging materials and insulated packaging systems, how they work and which industries are using them for in-transit temperature control.

What Is the Primary Function of Insulated Packaging?

Insulated packaging for shipping is designed to maintain the temperature of whatever’s inside, whether it’s pharmaceuticals or fresh flowers. Insulated packaging for food is widely used to protect sensitive products like meat, dairy and fresh produce from fluctuating temperature during shipment. It’s essential for preserving integrity and freshness, maintaining safety and quality, and preventing loss. Insulation packaging keeps sensitive products protected and at a stable temperature during cold chain transportation.

What Are the Different Types of Insulation Packaging?

Fortunately, you can choose from a number of insulated packaging systems today, depending on your specific needs. Let’s compare some of the most popular cold chain shipping options.

• Cardboard
• Polyethylene Foil & Air Bubble
• Polyurethane Foam
• Expanded Polystyrene (EPS)

Cardboard

Cardboard may not be the first material that springs to mind when you think about insulated packaging, but paper actually does a good job of trapping heat or cold inside and keeping the opposite extreme out. Insulated cardboard shipping boxes and containers maintain a stable temperature by trapping thousands of minute air pockets in between layers of compressed paper. These air pockets form a barrier that slows the transfer of heat.

Insulated cardboard boxes are one of the most common types of insulated packaging for food, used to transport perishable food and beverage products like dairy goods, meat products and fresh produce, as well as temperature-sensitive beverages like wine. Cardboard insulated packaging for shipping is also used to protect pharmaceuticals and temperature-sensitive vaccines during transit, maintaining their chemical integrity and safety.

Advantages of Cardboard Insulated Packaging

Cardboard insulated packaging is much more affordable than many of its counterparts. It’s lightweight and versatile, with various size boxes and shipping containers available to suit virtually any need. Collapsing cardboard containers for shipment and storage saves space and reduces costs. Plus, cardboard is easily recyclable, which appeals to eco-conscious consumers. This can help boost your brand reputation while also reducing your environmental impact. As a highly effective insulation material, cardboard is the go-to for many industries and brands.

Disadvantages of Cardboard Insulated Packaging

Cardboard’s limited temperature control means it may not be effective for all cold chain shipping requirements, especially across long distances. Extreme heat or cold can weaken cardboard, putting its contents at risk. It’s also susceptible to moisture damage unless the container has been treated, which makes it non-recyclable. Cardboard is not suitable for super heavy items, and it’s often a single-use product, which can drive up costs.

Polyethylene Packaging – Foil & Air Bubble

Another popular cold chain packaging option is polyethylene packaging, which is basically a bubble mailer with a foil exterior, made from low-density polyethylene plastic. The interior bubble-wrap layer insulates and protects the contents while the outer reflective layer protects against heat from the sun and UV rays.

With up to 24 hours of thermal protection, foil bubble insulated packaging is used to ship food products like pre-made meal kits, chocolate-dipped strawberries and other fresh goods being sent overnight or same-day express. Commonly called foil bubble mailers or cold chain mailers, these packages are available in a variety of shapes, sizes and thermal abilities.

Advantages of Polyethylene Insulated Packaging

Foil bubble mailers are tear-resistant, puncture-resistant and temperature safe. They’re lightweight and affordable, and take up minimal storage and shipping space, making them a cost-efficient option. In addition to maintaining the internal temperature, foil bubble mailers can also control moisture and prevent odors from escaping. Some foil bubble mailers are recyclable at certain facilities and have a high value when returned.

Disadvantages of Polyethylene Insulated Packaging

For products with extreme temperature needs, polyethylene packaging doesn’t offer enough thermal protection, which limits its use for cold chain shipping over extended time or distance. A foil bubble mailer may keep food frozen overnight, for example, but not over a period of two to three days. Additional ice packs and insulation can help, but this also drives up costs and shipping weight. Foil bubble mailers can’t be curbside recycled, making them a less eco-friendly option for consumers who don’t want the responsibility of returning used packaging to a specific recycling facility.

Polyurethane Foam Packaging

Polyurethane foam packaging is a cold chain power player, especially for shipments requiring super-low temperatures over a longer period of time. Each square inch of polyurethane foam contains literally millions of minuscule air pockets that maintain the temperature, while an additional barrier film reflects radiant heat from the exterior. The result is superior thermal protection that, when paired with ice packs, makes this the best option for goods that need to stay frozen.

Polyurethane foam insulated packaging systems are used for shipping temperature-sensitive pharmaceuticals and vaccines, which can require very specific temperatures to ensure efficacy. This type of cold chain system is also used for shipping temperature-sensitive food products as well as storing perishable products in insulated warehouses. Food delivery services use polyurethane foam insulated bags to keep contents hot, including pizza delivery bags as well as the food bags used by popular services like DoorDash and Uber Eats.

Advantages of Polyurethane Foam Insulated Packaging

In addition to excellent thermal protection, polyurethane foam packaging is moisture resistant, fire resistant and provides protection against dropping, bumps and other types of impact. For pharmaceuticals that are subject to government regulation of shipping temperatures, polyurethane foam can help maintain compliance. Foam can be cut into custom shapes to meet specific shipping needs and is lightweight enough that it won’t significantly increase shipping costs.

Disadvantages of Polyurethane Foam Insulated Packaging

Polyurethane foam doesn’t do well in direct sunlight, which may impact its effectiveness in certain shipping environments. Compared to other types of thermal insulation packaging, it tends to have a higher price point. The flammable nature of polyurethane foam may require flame retardants to comply with safety standards, further adding to costs. Polyurethane foam packaging is not biodegradable, making it less eco-friendly than options like cardboard.

Expanded Polystyrene (EPS) Packaging

One of the most commonly used insulated packaging systems is the expanded polystyrene (EPS), or Styrofoam, cooler. These gained massive popularity because they’re lightweight, affordable and widely available; you can buy one at just about any grocery store. Throw in a couple ice packs and they do a great job of keeping your food and drinks cold, even on a hot summer day.

Polystyrene packaging including Styrofoam coolers and trays are also used for shipping temperature-sensitive food products, like fresh seafood and meat. Its excellent thermal performance keeps these products safe for consumption, even when shipping over long distances. EPS trays are used to transport pharmaceuticals and sensitive medical equipment that requires temperature control as well as protection; for example, fragile test tubes containing blood samples.

Advantages of EPS Insulated Packaging

Polystyrene packaging is sturdy, durable and offers excellent thermal performance over a longer period of time than some insulated options, like foil air bubble mailers and cardboard insulated containers. EPS is lightweight and widely available, and it can be molded into virtually any shape to meet custom shipping needs. Styrofoam coolers can often be reused and are recyclable at the end of their life.

Disadvantages of EPS Insulated Packaging

Styrofoam packaging takes up a lot of space, making it less cost effective to ship and store. Although EPS is recyclable, it requires a unique process and isn’t accepted by most curbside recycling programs. Because consumers have to drive EPS packaging to a drop-off recycling center that takes it, most of it ends up in the trash and eventually in landfills, where it can take hundreds of years to decompose. This environmental impact is why some countries are starting to ban Styrofoam entirely.

How Ernest Can Help With Insulated, Temperature Control Packaging Design

If you need insulated, temperature-controlling packaging solutions, Ernest has you covered.. We have a resident cold chain expert and a team of design pros on hand who love finding the perfect solution to get any product from point A to point B without compromising temperature or integrity.

See for yourself how we helped Commodity Forwarders Inc. realize serious savings with a custom cold chain packaging solution that prevents spoilage and losses while reducing the company’s carbon footprint. Ready to get to work? Let’s talk.