Which cold chain packaging you need depends on four things: how cold your product must remain, how long it is in transit, under what conditions it travels and how large the shipment is. With those four answers, you can choose the right combination of box, insulation and coolant in just a few minutes. This guide takes you through it step by step — including ready-made example combinations for each sector.
Cooled Solutions has been a Dutch manufacturer of cold chain packaging since 1972. We work with you rather than simply selling you products: the packaging has to be right — not too lightweight, and not unnecessarily expensive.
- What temperature? Frozen, chilled (2–8 °C), cool, or protected against heat.
- How long in transit? From a few hours to several days.
- Under what conditions? Summer or winter, small parcel or pallet.
- Which material is suitable? EPS, EPP, honeycomb or thermal pallet cover — plus the right coolant.
Step 1 — Determine your temperature zone
First determine the temperature limits within which your product must remain. This determines both the coolant and the amount of insulation you need.
| Zone | Temperature | Typical products | Suitable coolant |
|---|---|---|---|
| Frozen | below -18 °C | ice cream, frozen meat and fish, frozen pharmaceuticals | dry ice or ample ice packs (on advice) |
| Chilled | 2–8 °C | meat, fish, dairy, meals, medicines, vaccines | gel packs / ice packs or PCM +5 °C |
| Cool | 8–15 °C | chocolate, plants, cosmetics, wine | a few gel packs or PCM, above all good insulation |
| Protected (CRT) | 15–25 °C | products that must not get warm, room-temperature controlled pharmaceuticals | insulation + PCM at room temperature |
Unsure between two zones? Choose the strictest (coldest) requirement — then you are always on the safe side.
Step 2 — Estimate your transit time
The time between dispatch and arrival determines how much cooling and insulation is needed. Always calculate using the longest realistic delivery time, including possible delays or a weekend in between.
| Transit time | Recommended setup | Example |
|---|---|---|
| Up to 24 hours | Good cooling box (EPS or honeycomb) + coolant | EPS box + 2–3 gel packs |
| 24–48 hours | Extra insulation (thick wall or thermal box) + more coolant | Thermal box 4-layer + ice packs or PCM |
| 48–72 hours | Maximum insulation + PCM or ample cooling | Thermal box 6-ply or EPP + PCM packs + data logger |
| 72+ hours | Custom solution — have the performance validated | Combination on advice, with temperature validation |
Step 3 — Take environment and size into account
Season and outside temperature
A shipment left for hours on a warm loading dock in summer needs more cooling than the same shipment in winter. At high outside temperatures or with unknown waiting times, increase the number of gel packs and choose thicker insulation.
Shipment size
The larger and heavier your product, the more thermal mass — and that works to your advantage, although large boxes also lose more heat through their walls. For small parcels, a thin wall is often sufficient; for pallets and large loads, choose thermal pallet covers, insulation film or container liners.
Step 4 — Choose the right insulation material
The box or cover determines how well the cold stays inside. Each material has its own strengths:
| Material | Insulation | Weight | Sustainability | Best for |
|---|---|---|---|---|
| EPS (styrofoam / tempex) | Very good | Lightweight | Recyclable | Fish, meat, food and pharma — most shipments |
| EPP | Excellent | Lightweight and strong | Reusable | Return logistics and high-value pharma |
| Honeycomb cardboard | Good | Lightweight | Fully paper-recyclable | E-commerce and sustainable shipments |
| Thermal pallet covers & film | Good (reflective) | Very lightweight | Reusable | Pallets, air freight and large loads |
The workhorses. Thin wall for lightly chilled transport, thick wall for long or demanding cooling, with or without drain holes (for fish and ice).
Ready-to-use insulated boxes. 4-ply for medium-length transit, 6-ply for the most demanding chilled and frozen requirements.
EPP for reusable, robust solutions. Honeycomb for a plastic-free, clean appearance that can be fully disposed of with waste paper.
For pallets, air freight and sea containers: thermal pallet covers, insulation film, insulated liners and container liners.
Step 5 — Choose the right coolant
The coolant does the actual work: it keeps the contents cold. The choice follows directly from your temperature zone.
| Coolant | Works around | Best for | Please note |
|---|---|---|---|
| ice packs / ice packs | 0 °C | refrigerated shipments (2–8 °C) | fully freeze through in advance |
| ice pack sheets | 0 °C | flat cooling, meal boxes, e-commerce | flexible, easy to position |
| Reusable gel packs | 0 °C | return systems, frequent shipments | intake/return logistics required |
| PCM packs | adjustable (e.g. +5, +21 or -20 °C) | pharma and long transit — stable temperature | pre-condition to the correct temperature |
| Dry ice | -78 °C | frozen goods and very long transit | safety, ventilation and air freight regulations (on advice) |
Rule of thumb: more coolant for longer transit times, higher outside temperatures and a lighter box. For a chilled shipment of up to 24 hours in a well-insulated box, 2 to 3 gel packs are often sufficient; for 48–72 hours or in summer, scale this up or switch to PCM. The exact quantity depends on your product — preferably have a new setup validated once with a data logger. Are you shipping fish, meat or moist products? Then add an absorbent mat to prevent leakage moisture.
View the full range of coolants, ice packs and PCM packs.
Quick selection by sector
Do you know which sector you are in? Then go directly to the right selection:
Meat, fish, dairy and meals. Usually EPS + gel packs, often with an absorbent mat.
View selection →GDP-compliant solutions with PCM and data logger for 2–8 °C and ambient controlled transport.
View selection →Cooling with protection against pressure loss and moisture damage for vegetables, fruit and cut flowers.
View selection →IATA-compliant thermal pallet covers and insulation for pallets and long international transit.
View selection →Quick-to-pack, clean and scalable solutions — honeycomb or EPS with ice pack sheets.
View selection →Example combinations
For inspiration — proven combinations our customers use every day. Adapt them to your transit time and season.
EPS box with thick walls + 2–3 gel packs + absorbent mat against leakage moisture.
Honeycomb or thin-walled EPS + ice pack sheets. Clean, fully recyclable appearance.
EPS box with drainage holes + ample ice packs, so meltwater can drain away.
Thermal box 6-layer or EPP + PCM +5 °C + data logger. GDP-compliant.
Thick-walled EPS + plenty of ice packs, or dry ice on the advice of our specialists.
Thermal cover over the pallet + insulation film. IATA-compliant for long transit.
Checklist before you order
- Temperature zone determined (frozen / refrigerated / cool / protected)
- Longest realistic transit time estimated, including delays
- Season and waiting times taken into account
- Insulation material and box size selected
- Sufficient coolant, pre-conditioned
- When in doubt: setup validated once with a data logger
Our advisors will help you choose the right combination and can send samples or a trial setup if required. Advice is free and without obligation.
Request advice or a quoteor call +31 (0) 255 234 200For large volumes and regular customers
As a Dutch manufacturer, we supply not only individual packaging, but also structural solutions for companies shipping at larger scale:
Competitive bulk pricing for larger volumes, and annual contracts with fixed rates for regular customers.
Production in the Netherlands and custom sizes made to order, with short communication lines and lead times of 2–4 weeks.
Your own branding on the box, or supplied completely neutral — ideal for distributors.
On pallets, on demand, within agreed time slots — and, if required, directly to your end customers.
On request, we provide product specifications and datasheets, material certifications (FSC, food-contact, REACH), validation reports for temperature performance, and CO₂ impact calculations. Read more about the options for suppliers and distributors or request a quote directly.
Want to know more? View the frequently asked questions or the glossary explaining commonly used terms.