Polystyrene boxes vs honeycomb cold boxes: which should you choose?
Short answer: choose an EPS box if cost efficiency, proven performance and moisture resistance come first (long or humid shipments). Choose a honeycomb cooler box if sustainability is the priority: it is 100% recyclable through the waste paper stream, with a comparable insulation value, but slightly more expensive and less resistant to prolonged moisture.
When choosing the right cooler box for your shipment, the material plays an important role. EPS (expanded polystyrene, also known as styrofoam or Tempex) and honeycomb cardboard are both widely used solutions, but each has its own advantages and disadvantages.
EPS boxes: proven insulation
EPS boxes have been the standard in temperature-sensitive transport for decades. They offer:
- Excellent insulation (lambda value ~0.035 W/mK)
- Low price per unit
- Lightweight
- Resistant to moisture
- Different wall thicknesses possible
Disadvantage: less sustainable, not biodegradable, recycling is possible but requires specialist processing.
Honeycomb cooler boxes: sustainable alternative
Honeycomb cardboard is made up of hexagonal cells between two layers of cardboard. Advantages:
- 100% recyclable through the regular paper stream
- Comparable insulation value to EPS
- Sturdy construction
- FSC-certified cardboard possible
- Attractive for brands with a sustainability focus
Disadvantage: slightly more expensive than EPS, less resistant to prolonged moisture.
Which do you choose?
Choose EPS if: cost efficiency and proven performance come first, or for longer shipments in humid conditions.
Choose honeycomb if: sustainability is a priority for your brand or customers, or for standard transport within Europe.
In doubt? Contact our sales support team for advice for your situation.
The comparison at a glance
| Point | EPS box | Honeycomb cooler box |
|---|---|---|
| Unit price | Often lower | Slightly higher |
| Weight | Very light | Depends on the design |
| Moisture | Absorbs little moisture | More sensitive to prolonged moisture |
| Waste after use | Separate collection or processing | Via the waste paper stream |
| Shipping appearance | Functional | Looks like ordinary cardboard, easy to print on |
| Storage when empty | Takes up a lot of space | Depends on the model |
The actual holding time depends on the outside temperature, the fill, the wall thickness and the cooling elements. Always compare boxes with the same inner dimensions and a comparable construction.
What to watch for with moisture
Cold products and coolants cause condensation. EPS absorbs little moisture and therefore keeps its shape. Honeycomb cardboard is paper. If the route is short and dry, that is rarely a problem. If the shipment is in transit for a long time, stands outside or you ship products that give off moisture themselves, it pays to test. Put the product in a sealed bag or tray, and use absorbent material if leakage can occur. You will find handy options under absorbent pads.
What to watch for with sustainability
A more sustainable choice is more than a material name. Think of the full picture:
- What does your customer do with the box? If the recipient has a paper bin to hand, honeycomb is practical. If they have a collection point for polystyrene, EPS can also be disposed of properly.
- How often does something go wrong? A box that does not protect the product is always the worst choice for the environment, because the product is lost.
- How much air are you shipping? A smaller box requires less material and less transport volume. See also choosing the right box size.
You can read an honest comparison in is EPS bad for the environment. You will find more about disposal in disposing of and recycling polystyrene foam.
How to test both materials with your own shipment
- Choose an EPS box and a honeycomb box with the same inner dimensions.
- Fill both with your product and the same quantity of cooling elements.
- Put a data logger in each box.
- Send both over your longest and warmest route.
- Compare the temperature curve, the condition of the product and the condition of the box on arrival.
With this test you have figures from your own situation. That is more reliable than a general comparison.
Is there a third option?
Yes: EPP. That material is more sturdy and suitable for reuse. You can read the difference from EPS in EPS or EPP: which box do you choose?. You will find our range of EPP boxes in the web shop.
Frequently asked questions
Is honeycomb always more sustainable than EPS?
Not automatically. It depends on disposal, transport volume and whether the product arrives undamaged. Honeycomb has the advantage of the paper stream. EPS has the advantage of low weight.
Can I use EPS for food products?
EPS is widely used for packaging and chilled shipping of food products and does not absorb moisture or odour. We are happy to answer questions about conformity for your application.
Which cooling elements go with which box?
That depends on the inner dimensions, the transit time and the outside temperature. The calculation method is set out in how many gel packs do you need per shipment.
Can I use both materials side by side?
Yes. Many companies choose per product or per customer group. For example, honeycomb for brand-sensitive consumer shipments and EPS for long or wet routes.
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Need the right packaging straight away? View our EPS boxes, honeycomb cooler boxes and cooler boxes.
