Insulated bubble mailer with aluminum: how it insulates
An insulated bubble mailer with aluminum insulates by combining two properties: the bubbles trap air and the aluminum layer reflects heat radiation. As a result, the contents warm up more slowly. This is how our insulated mailer works, made for small, temperature-sensitive shipments. Below you can read what each layer does and what the mailer cannot do.
How does an insulated bubble mailer insulate?
The bubbles in the film trap air. That still air forms an insulating layer. The metalized aluminum layer reflects heat radiation from outside. And the bubble structure absorbs shocks, so the contents are also less likely to be damaged.
Together they slow the warming of the contents. This is passive insulation: the mailer does not cool by itself and does not measure anything. For a cool product, add a gel ice pack or cooling element, see our ice packs.
Mailer with aluminum or plain bubble mailer: what is the difference?
Bubble wrap is film with air bubbles. A bubble mailer comes in two versions. Plain bubble wrap is meant to protect against shocks, scratches, moisture and dust. A bubble wrap mailer with an aluminum layer adds something to that: the reflective layer blocks heat radiation.
| Property | Plain bubble wrap | Mailer with aluminum |
|---|---|---|
| Shock absorption by air bubbles | Yes | Yes |
| Reflective aluminum layer | No | Yes |
A bubble wrap mailer without aluminum therefore insulates less well against heat radiation than a mailer with aluminum. If you want to send a chilled shipment, choose the version with the aluminum layer.
Which version is an insulated mailer?
Our insulated mailers are bubble wrap envelopes with a metalized aluminum layer and a self-adhesive strip. We supply them in four sizes: 30 x 45, 35 x 35, 45 x 45 and 60 x 60 cm. The mailer closes quickly and neatly without tape. If you open it carefully, you can reuse it.
The four sizes in the product data
| Size | Outer dimensions | Product description says |
|---|---|---|
| 30 x 45 cm | 300 x 450 mm | elongated, for medicine vials, ampoules and elongated pharmaceutical packages |
| 35 x 35 cm | 350 x 350 mm | square, for standard small boxes, jars and compact pharmaceutical packages |
| 45 x 45 cm | 450 x 450 mm | roomy, for larger products or several items in one shipment |
| 60 x 60 cm | 600 x 600 mm | largest size, for large or bundled products |
All four have bubble wrap with a metalized aluminum layer and a self-adhesive strip, and are available per piece.
Also read which other names cover the same product in insulated mailer, insulated envelope or thermal envelope.
What can an insulated bubble mailer not do?
A mailer with aluminum is not a refrigerator. It slows the warming of the contents but does not hold a temperature. How long the product stays cold depends on the outside temperature, the amount of product, the cooling element and the travel time. We therefore state no fixed duration.
For larger or heavier shipments, choose other packaging, such as an insulated shipping bag in a shipping box or an EPS box. For the difference between the two, read insulated shipping bag or EPS box.
How to combine the mailer with a cooling element
Choose a size that is just a little larger than product plus cooling element. Add one or more gel ice packs next to the product and close the mailer with the adhesive strip. For good temperature control, place the mailer in a sturdy insulated shipping box.
Why aluminum and not just air?
Air in bubbles slows heat transfer through the mailer. But heat also travels as radiation. That is where the aluminum layer comes in: it reflects heat radiation. A mailer with only bubble wrap lacks that second mechanism.
For small shipments this combination is practical. The mailer is light, flat and quickly closed. If you have more contents, choose a larger size from the insulated mailer series or other packaging.
This is passive protection. You can read more about the rest of the chain in our article on 5 common mistakes when shipping chilled.
Bubble wrap with aluminum on rolls
We also sell bubble wrap with aluminum as insulation film on rolls. The rolls have a core of 76 mm. These versions are in our product data:
| Roll | Construction | Area |
|---|---|---|
| 150 cm x 50 m x 4 mm | aluminum + bubble wrap | 75 m² |
| 150 cm x 100 m x 3 mm | aluminum + bubble wrap + aluminum | 150 m² |
| 150 cm x 50 m x 3 mm | aluminum + bubble wrap + aluminum | 75 m² |
| 125 cm x 50 m x 3 mm | aluminum + bubble wrap + aluminum | 62.5 m² |
| 150 cm x 50 m x 2.7 mm | Metalized PET + bubble wrap | 75 m² |
| 75 cm x 100 m x 2.7 mm | Metalized PET + bubble wrap | 75 m² |
The roll of 75 cm width states how the two types of layer differ: the MPET coating protects against radiation from outside and gives a higher reflection. Aluminum has a higher density and, according to that description, protects better against radiation from outside.
We also supply bubble wrap without aluminum on rolls, made of transparent LDPE: 50 cm x 100 m (50 m²) and 150 cm x 50 m (75 m²), both with a film thickness of 50 µm. The description mentions shock absorption and protection against moisture and dust.
Which products is the mailer suitable for?
The insulated bubble mailer with aluminum is used most in the pharmaceutical sector, for medicines, vaccines and samples. Companies also use it for small shipments of perishable food, cosmetics and temperature-sensitive e-commerce orders.
Frequently asked questions about the insulated bubble mailer
Is a bubble wrap mailer enough to ship cold?
Plain bubble wrap absorbs shocks but has no aluminum layer. For chilled shipments, choose the mailer with aluminum and add a gel ice pack.
What does the aluminum in the mailer do?
It reflects heat radiation. Together with the air in the bubbles, this slows the warming of the contents.
What do companies use an insulated bubble mailer with aluminum for?
Most in the pharmaceutical sector, for medicines, vaccines and samples. Also for food, cosmetics and smaller online shop orders that have to travel chilled.
Which sizes of bubble wrap mailers with aluminum are there?
30 x 45, 35 x 35, 45 x 45 and 60 x 60 cm, all with an adhesive strip and available per piece.
Can the mailer be reused?
Yes, if you open it carefully.
How does the mailer close?
With a self-adhesive strip, quickly and neatly and without tape.
Order an insulated bubble mailer
View our insulated mailers with aluminum layer and adhesive strip. They are from our own production since 1972 and available from stock.
You will find all names in our glossary.
