Packaging Corner: Keep it cool and green

To keep temperature-sensitive products—such as medications or foods—from spoiling during shipping, packagers have long relied on non-biodegradable polystyrene foam coolers. But to meet increasing interest in sustainability, the team at Thermal Packaging Products, a division of MP Global Products, developed an alternative.

Using recycled cotton fibers diverted from landfill, the company manufactures temperature-sensitive packaging in two forms: box liners and envelopes. Either can be made to specific custom sizes and in a range of thicknesses and densities.

“Typically, the thicker the insulation, the higher the R-value, or resistance to heat gain or loss,” explains Roger Borgman, national sales manager. “Depending on how long an item will be in transit, shippers can choose various thicknesses to achieve their required R-value.”

The cotton insulation contains an anti-microbial and is encapsulated in recyclable poly film that has been specially formulated to promote biodegradation. Recipients can either separate the cotton from the plastic, putting the former in the trash and the latter in recycling, or toss it all in the trash.

Further, “the package’s recipient doesn’t have to figure out where to store the foam coolers until they can dispose of them, or find a special recycling center,” Borgman says. “Our products ensure a positive customer experience.”

An additional benefit of the cotton insulation is in its inherent cushiness. The soft, pliable padding cradles the items, protecting them from shocks or drops that could cause damage.

For flexibility, the reversible box liners include two different facings: a perforated side to wick away condensation from thawing gel packs, and a heavier film for use with dry ice. The envelopes work with frozen gel packs and include a sealable interior pouch to keep contents secure. Because they can be tightly compressed and shipped flat when palletized, both solutions save space at a packaging facility.

“A single pallet holds 300 of our 12 x 12 x 12-inch box liners, whereas the same number of foam shippers might require up to four pallets,” adds Borgman, who adds that there are further cost savings in transportation, warehousing and labor associated with handling the foam.

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