How to Choose the Right Chilled Packaging for Your Business
Whether you’re shipping fresh food, temperature-sensitive pharmaceuticals, or subscription meal kits, the success of your cold chain logistics hinges on one vital component: the right chilled packaging.
Selecting the right chilled packaging is more than just picking an insulated box. It requires a balance of size, insulation performance, shipping duration, regulatory requirements, and environmental impact.
In this buyer’s guide, we break down everything you need to know to choose the best chilled packaging for your business, featuring standout products like EcoWool, Thermapack Double, CoolaGels, and CoolaPacks from TPS.
Why Chilled Packaging Matters
Chilled packaging is designed to maintain a safe temperature range for perishable goods during transit. Without it, products can be exposed to fluctuating temperatures, leading to spoilage, regulatory breaches, and unhappy customers.
From e-commerce food deliveries to biopharmaceutical distribution, chilled packaging plays a critical role in:
● Extending product shelf life
● Meeting food and pharma compliance
● Protecting brand reputation
● Reducing return rates and wastage
1. Assess Your Product & Payload Size
Start by identifying what you’re shipping:
● Is it fresh, frozen, or ambient?
● How sensitive is it to temperature change?
● How much does it weigh?
These answers will help determine:
● Internal packaging volume required
● Type and quantity of refrigerants (gel packs, PCMs)
● Box and liner dimensions for an optimal fit
Pro Tip: Avoid oversized boxes that increase dead space, requiring more refrigerant and risking uneven temperature distribution.
2. Define Your Shipping Duration & Route
Time in transit has a direct impact on the packaging system needed.
● Short Haul (0–12 hrs): Basic insulation and minimal refrigerant
● Medium Haul (12–48 hrs): Requires layered insulation and gel packs
● Long Haul (48+ hrs): High-performance insulation + Phase Change Materials (PCMs)
Also consider the shipping environment:
● Will it pass through hot or cold climates?
● Is it air, land, or sea freight?
● Will it be held in depots or left unattended?
Choosing a solution that matches your worst-case scenario ensures better protection and customer satisfaction.
3. Understand Regulatory & Compliance Requirements
If you’re shipping:
● Food products: Comply with HACCP and food safety regulations
● Pharmaceuticals: Must meet Good Distribution Practice (GDP), MHRA, and FDA standards
● Biotech/lab samples: Often require ISO and GLP/GMP compliance
Look for packaging solutions that support:
● Validated performance testing
● Temperature monitoring compatibility
● Tamper-evidence and traceability
TPS offers packaging components designed to help meet these regulations with ease.
4. Choose the Right Insulation Material
There are several types of insulation materials available, each with its own pros and cons. Here are the main contenders:
Foil Liners
● Reflect radiant heat and reduce temperature gain
● Lightweight and compact
● Ideal for shorter shipments
● Often used in conjunction with gel packs
Featured Product: Thermapack Double
Thermapack Double is a high-performance twin-layer reflective foil liner from TPS. Its double insulation layers improve thermal performance for medium to long-distance chilled shipments. Compact and easy to use.
Wool Liners
● Natural or recycled insulation with excellent thermal performance
● Regulates moisture to reduce condensation
● Biodegradable or fully recyclable, and sustainable
● Ideal for longer shipping durations
Featured Product: EcoWool
EcoWool from TPS is filled with 64% recycled material. The wool liner is encased in recyclable film, offering excellent thermal protection for perishable goods. It's curbside recyclable and ideal for eco-conscious brands looking to maintain high cold chain standards.
5. Select the Right Refrigerant
Insulation slows down temperature change, but it doesn’t actively cool. That’s where refrigerants come in.
Options include:
● Gel packs: Simple and effective for short-to-medium durations
● Phase Change Materials (PCMs): Maintain specific temperatures (e.g., 2°C–8°C or -18°C) for longer
Featured Products: CoolaGels & CoolaPacks
CoolaGels and CoolaPacks from TPS are designed to keep products at stable chilled or frozen temperatures throughout transit. CoolaGels are gel-based refrigerants that are reusable and leak-resistant. CoolaPacks come in a sheet of 12 cells (4×3) and can be cut into various sizes to suit different packaging volumes.
Make sure refrigerants are:
● Properly conditioned before use (frozen or refrigerated to spec)
● Placed above and around the payload to ensure full coverage
● Sized appropriately for the box and duration
6. Consider Ease of Use & Operational Efficiency
Packaging that’s difficult to assemble can slow down your fulfilment process.
Look for systems that:
● Are easy to pre-pack
● Include clear instructions
● Allow for quick refrigerant placement
● Have minimal components to reduce packing time
EcoWool, Thermapack Double, and TPS refrigerants all offer intuitive, easy-to-use designs compatible with most logistics operations.
7. Evaluate Environmental Impact
Sustainability is no longer optional for most businesses.
● Use recyclable or compostable materials (like EcoWool)
● Choose lightweight options to reduce your carbon footprint (like ThermaPack Double)
● Partner with suppliers who prioritise ethical sourcing and low-impact manufacturing
TPS is a UK-based manufacturer with a strong focus on local sourcing, reducing transport emissions and supporting sustainable innovation.
Real-World Applications by Industry
● Meal Kits: Use EcoWool or Thermapack Double for longer routes; pair with CoolaGels
for multi-day deliveries.
● Pharma: Combine foil insulation with CoolaPacks and monitoring devices for
GDP-compliant shipments.
● Cosmetics: Use compact foil liners with CoolaGels for lightweight, chilled protection.
● Dairy & Fresh Produce: EcoWool + CoolaPacks manage moisture and maintain
optimal freshness in transit.
Conclusion: Choose Smart, Ship Safer
The wrong chilled packaging can cost you customers, compliance, and profit. The right solution, however, ensures that your product reaches its destination in perfect condition while supporting your brand values and operational efficiency.
By considering factors such as size, shipping duration, compliance, insulation type, refrigerants, and sustainability, your business can make smarter choices for the long term.
For innovative and eco-conscious chilled packaging solutions like EcoWool, Thermapack Double, CoolaGels, and CoolaPacks, visit www.thermalpackaging.co.uk
Need help selecting the ideal packaging for your products? Get in touch with TPS for tailored recommendations based on your route, payload, and compliance needs.