Packaging Hero

Why Insulated Shipping Matters

Shipping temperature-sensitive products such as seafood, meat, dairy, pharmaceuticals, and laboratory samples, requires strict temperature control from origin to destination. Without proper insulated packaging, these goods are vulnerable to spoilage, temperature fluctuations, and regulatory non-compliance.

Today’s insulated shipping solutions are designed to meet diverse cold chain requirements. From simple foam containers to advanced multi-layer liners and cooling packs, businesses can choose packaging tailored to their specific needs. Packaging HERO offers a wide range of options to support reliable cold chain shipping.

Common Products That Require Insulated Packaging

Frozen meat and poultry

Ice cream and frozen desserts

Fresh seafood

Vaccines and biologics

Laboratory specimens

Meal kits and ready-to-cook foods

Specialty chocolates and baked goods

Types of Insulated Shipping Solutions

Foam Coolers with Outer Boxes: Best suited for frozen foods, seafood, and medical supplies, foam coolers provide excellent thermal insulation and structural protection. These EPS containers maintain internal temperatures effectively and are paired with corrugated boxes for durability and labeling. They are reusable and available in multiple sizes.

Insulated Box Liners: A flexible and cost-effective solution, insulated liners transform standard shipping boxes into temperature-controlled containers. Made from foil or metalized film with thermal padding, they ship flat for easy storage and are ideal for meal kits, perishable foods, and eCommerce deliveries.

Cold Gel Packs: Gel packs are a dependable, reusable cooling option for maintaining chilled conditions during transit. Available in various sizes, they are commonly used for fresh produce, dairy, and cosmetics, especially for short- to mid-range shipping durations.

Dry Ice Packs and Foam Bricks: Designed for deep-frozen shipments such as ice cream, these solutions support extremely low temperatures without leakage. They are ideal for products requiring extended freezing conditions.

Thermal Bubble Mailers: Lightweight and moisture-resistant, thermal bubble mailers combine cushioning with reflective insulation. They are best for small items like pharmaceuticals, cosmetics, and vitamins.

Insulated Pallet Covers: For bulk shipments, insulated pallet covers protect large quantities of temperature-sensitive goods. They are commonly used in LTL and freight shipping to maintain consistent temperatures across entire pallets.

Choosing the Right Packaging

Selecting the appropriate insulated shipping solution depends on several key factors:

Transit Time: Longer shipping durations require stronger insulation and more cooling material.

Product Sensitivity: Highly sensitive items like biologics or frozen foods need higher-performance packaging.

Shipment Size: Foam coolers provide structure for larger shipments, while liners are more space-efficient for smaller orders.

Budget and Sustainability: Liners and gel packs are often more economical and require less storage space.

Combine Materials for Maximum Protection

The most effective cold chain systems use a combination of insulated packaging, cooling elements, and moisture barriers. For example, placing frozen gel packs inside a foam cooler and enclosing it in a corrugated box is a proven method for shipping frozen seafood or perishable items over extended periods.

Final Thoughts

Whether you are shipping frozen meals across the country or ensuring pharmaceutical compliance on regional routes, choosing the right insulated shipping boxes & supplies is essential for maintaining product quality and safety.

When it comes to packaging and shipping, corrugated boxes are one of the most commonly used solutions worldwide. Although many people use the terms corrugated boxes and cardboard interchangeably, they are not the same. Understanding the difference can help businesses choose the right packaging for protection, cost efficiency, and sustainability.

What Are Corrugated Boxes?

Corrugated boxes are made from corrugated fiberboard, a strong and lightweight material consisting of three layers:

Outer linerboard

Inner linerboard

Fluted medium sandwiched between the liners

The fluted (wavy) layer provides strength, cushioning, and resistance to crushing, making corrugated boxes ideal for shipping, storage, and handling of goods. They are widely used across industries such as e-commerce, food & beverage, electronics, pharmaceuticals, and logistics.

What Is Cardboard?

Cardboard is a broad, informal term often used to describe paper-based packaging materials. In most cases, it refers to paperboard, which is a single-layer or solid sheet material without fluting. Cardboard is typically thinner and less durable than corrugated fiberboard.

Paperboard is commonly used for:

Cereal boxes

Shoe boxes

Cosmetic and retail packaging

Lightweight consumer products

Key Differences Between Corrugated Boxes and Cardboard

Structure: Corrugated boxes have three layers with a fluted middle; cardboard is single-layer and solid

Strength: Corrugated boxes are strong and crush-resistant; cardboard is lighter and less durable

Protection: Corrugated boxes provide cushioning for heavy or fragile items; cardboard offers minimal protection

Usage: Corrugated boxes are used for shipping and logistics; cardboard is used for retail and light packaging

Why Corrugated Boxes Are Preferred for Shipping

Corrugated boxes are specifically designed to withstand stacking, rough handling, and long-distance transportation. Their fluted structure absorbs shocks and distributes weight evenly, reducing product damage during transit. Additionally, corrugated packaging is recyclable, biodegradable, and cost-effective, making it an environmentally friendly choice.

Customized packaging made its debut in the 1890s when Nabisco first featured a boy in a raincoat on their product. Since then, packaging has evolved drastically. Some major milestones include Coca-Cola’s introduction of the iconic contour bottle, Tide’s use of vibrant colors to catch the eye of consumers, and Andy Warhol’s 1962 artwork on Campbell’s Soup cans, which blurred the lines between art and advertising. These are just a few examples; there have been many more. But one thing remains clear: customized packaging is a powerful tool in shaping how consumers perceive your brand. This blog explores just how much impact packaging can have on your company’s image.

The Impact of Customized Packaging on Consumers

There are many ways to customize your packaging, from adding your logo and brand colors to using different materials or even personalized stickers. The key is to stand out and differentiate yourself from your competitors. One thing is certain, if your packaging isn’t branded, you're missing out. Here’s why:

Research shows that consumers form opinions about a brand within just the first seven seconds of seeing a product. According to Ipsos, 72% of consumers say product packaging design and 67% point to the materials used as the main factors influencing their buying decisions. Sustainable packaging, in particular, plays a big role, two-thirds of Americans say they consider it when deciding what to buy.

The Effect of Customized Packaging on Your Business

In the business world, the stakes are high. According to INC., 95% of new products fail. Why? Because consumers are often in a rush and they tend to choose products based on which packaging catches their eye. However, brands that invest in strong packaging see impressive returns. For example, MillerCoors saw a 5% increase in sales after rebranding their Miller Lite cans with a retro design. On average, businesses that focus on improving their packaging experience a 30% boost in consumer engagement.

The opposite is also true. When companies don’t customize their packaging, they risk falling behind. For example, in Australia, a plain packaging law for cigarettes was enacted about six years ago, preventing companies like Marlboro from using their iconic logos and fonts. This led to a significant drop in smoking rates, one of the largest declines in over 20 years.

The Bottom Line: Packaging Is as Important as the Product