Building the Ideal Insulated Packaging Solution
In the pursuit of an ideal insulated packaging solution, considerations such as environmentally sustainable materials, transit times, temperature requirements, packaging size, and compliance with regulations play vital roles. In this article, we take a close look at every factor you should consider when building your packaging solution.
TSS Thermalist
November 30, 2023 | Products
Insulated Packaging Solution
Factor 1: Packaging Materials
Kraft Paper Packaging
Kraft paper manufacturing is an environmentally sustainable process that utilizes various types of wood pulp. This material has gained popularity for producing boxes for a diverse range of products.
Recycled Wool
Recycled wool is made from post-industrial and post-consumer wool waste, such as discarded clothing and textiles. It is a sustainable alternative to new wool, as it reduces the need for virgin wool fibers and conserves resources. Recycled wool is also biodegradable, meaning it can break down naturally over time.
Plant Fibers
Plant fibers, such as bamboo, hemp, and sugarcane, are sustainable packaging materials that are renewable and biodegradable. They are used to make a variety of packaging products, such as bags, boxes, and wrappers. Plant fibers are a sustainable alternative to traditional packaging materials, but while they use natural materials, most are not recyclable and there are no currently effective plant-based thermal shipping materials that are biodegradable.
Expanded Polystyrene (EPS)
EPS, also known as Styrofoam, is a lightweight and insulating material used in packaging. It is made from petroleum and is not biodegradable, which has led to concerns about its environmental impact. EPS cannot be recycled, and it is bulky and fragile.
Polyethylene Terephthalate (PET)
PET is a widely used option because of its unique advanced recycling technology, which allows it to be infinitely recycled. Compared to alternative materials like cotton, denim, and paper, PET has a lower carbon footprint and can be easily scaled. Recycled PET not only tackles current pollution issues by removing waste from streams and giving them a second life, it also creates a product that can be recycled repeatedly, reducing its environmental impact and making it a top contender for sustainable packaging projects, as it helps reduce waste and conserve resources.
Factor 2: Transit Times
Timing plays a crucial role in cold chain shipping. When you select an insulated packaging material, the duration of the shipment needs to be a top consideration. Will you be using supplementary refrigerants, like dry ice and gel packs? This will also factor in to how you package your product for a specified duration.
It’s not enough to rely solely on the assurances from the supplier. It is essential to verify their claims with a test report, proving that the material can indeed perform as promised throughout the anticipated temperature conditions for the entire shipping duration.
Factor 3: Temperature Requirements
The type of the product being shipped will determine the temperature requirements. Chocolate has a different temperature range than fresh flowers. And some products, like pharmaceuticals, require very strict temperature ranges.
In addition, small healthcare products are particularly sensitive to temperature changes, demanding exacting specification. On the other hand, food and grocery products with substantial mass exhibit higher thermal inertia, making them less susceptible to heat absorption.
Factor 4: Packaging Size & Payload
The dimensions and configuration of your packaging in relation to the temperature-sensitive items is a critical point. Any void space within the package leads to thermal inefficiency. Therefore, it is essential to have a solution that precisely matches the size of your goods.
The choice of a solution will also depend on the quantity of the cargo being shipped. For smaller volumes or specific items, a single, compact temperature-controlled solution may suffice. However, when transporting larger quantities of pharmaceutical products, for example, larger options, such as pallet-sized solutions, may be necessary.
Factor 5: Compliance
The regulations governing the shipment of temperature-sensitive substances vary based on the origin and destination. Specific guidelines are established and monitored by region-specific organizations or government departments. In cases where the transported goods pose potential harm to humans or animals, strict adherence to the United Nations’ guidelines for transporting UN3373 Infectious Substances is imperative.
The Ideal Solution: Renewliner
A Case Study: Territory Foods
Territory is a healthy meal delivery service that partners with creative local chefs and their team of nutrition advisors to create tasty, clean meals. Territory recently launched Mealogic, a fulfillment and logistics platform providing other brands with best-in-class, ready-to-eat meals directly to customers through an expert network of chefs, food safety professionals, and other suppliers throughout the country.
In addition to needing a sustainable packaging option that aligned with their own company values, Territory faced steep challenges in demand planning. Volume was increasing rapidly, and other suppliers required more turnaround time and less cost-effective options than Territory could accommodate.
Renewliner from TSS proved to be the ideal solution. Territory researched other types of liners and insulation, and chose Renewliner because it is sourced from PET, a 100% recyclable plastic that is curbside recyclable, giving them the high level of sustainability that they were looking for.
TSS developed new shipper sizes and payload configurations to fit Territory’s meal trays. We prototyped, performed chamber testing, and conducted field testing. We tested the payloads with ISTA 7e standards, and recreated real world conditions during field testing.
We ultimately created four different payloads, as well as special buffer pads to minimize void space. In addition, we implemented panel inserts in the void space. The payloads created for Territory were based on their transit duration and required space.
We were careful to create packaging with dimensions that would provide favorable pricing for Territory. We used their own tools to price out volume configurations, solicited quotes from freight carriers, and developed the ideal box size for their needs.
TSS also worked with Territory to create demand planning timelines that ensured they have the inventory they need when they need it. And constant communication ensures every team is on the same page.
