EPS-Lined Insulated Shipping Box for Chilled & Frozen Food

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EPS-lined insulated shipping box with fitted foam cooler and lid

Tempk corrugated insulated shipper range

EPS-Lined Insulated Shipping Box for Chilled & Frozen Food

A corrugated shipping carton with a fitted molded EPS cooler and lid for chilled food, seafood, frozen ingredients, meal kits and perishable parcels. Tempk matches usable capacity, foam thickness and refrigerant layout to the payload, route and season.

Product format Corrugated outer carton with molded EPS body and fitted lid
Common planning sizes 5–45 L usable payload formats; custom dimensions available
Insulation planning 25–50 mm EPS wall thickness is a common starting range
Coolant compatible Conditioned gel packs, PCM packs, ice bricks and route-approved dry ice

A cold-food shipper configured as a complete packout

This shipper combines a protective corrugated carton with a lightweight molded expanded-polystyrene container. The close-fitting body and lid create a repeatable insulated cavity for gel-pack, PCM or dry-ice packouts, while dimensions, wall thickness, moisture control and coolant placement remain configurable for the buyer's product and distribution lane.

Fitted molded insulation

The one-piece EPS body and close-fitting lid help control open joints around the payload cavity and keep the packout repeatable.

Strong insulation-to-weight balance

EPS provides useful thermal resistance without adding excessive package mass to one-way parcel distribution.

Chilled and frozen flexibility

One shipper family can be configured around conditioned gel or PCM packs for chilled goods and dry ice for qualified frozen-food lanes.

Protective outer carton

The corrugated shell protects the molded foam during handling and provides a practical surface for tape, labels and custom print.

Repeatable packing workflow

Defined coolant positions, liners, dividers and fill limits help warehouse teams reproduce an approved packout.

Custom sizes and bulk supply

Tempk can adjust the carton, molded cavity, wall thickness, foam density, printing and component packing for the buyer's operation.

Product details

Brand Tempk
Product name EPS-Lined Insulated Shipping Box for Chilled & Frozen Food
Outer container Corrugated kraft shipping carton; board grade selected for payload weight, stacking and handling conditions
Inner container Molded expanded-polystyrene body with a fitted EPS lid
Typical usable payload volume 5–45 L parcel formats; smaller, larger and dimension-specific designs are available
Typical EPS wall thickness 25–50 mm common planning range; final thickness is selected against the route, season and packout
Typical EPS density planning Approximately 15–30 kg/m³, selected for the required mold strength and thermal design
Indicative EPS thermal conductivity About 0.038 W/(m·K) at 15 kg/m³ as a material reference; the declared value depends on grade, density and test temperature
Chilled programs Commonly configured for 2–8 °C or 0–10 °C with conditioned gel packs, PCM packs or ice bricks
Frozen programs Commonly designed around frozen payloads and an appropriate refrigerant; −18 °C and lower lanes normally need dry ice or another qualified frozen packout
Transit design target 24–48-hour parcel routes are a common development starting point; the complete system determines actual performance
Coolant options Gel packs, PCM packs and ice bricks for chilled lanes; dry ice only with suitable venting, separation, marking and carrier acceptance
Moisture control Optional watertight liner, product bags and absorbent pads for condensation, meltwater or liquid payload risks
Closure Fitted EPS lid inside a tape-sealed corrugated carton with route-specific handling labels
Customization Internal and external dimensions, foam thickness and density, board grade, printing, dividers, liner and coolant layout

Where it fits best

Chilled meal kits and prepared food

Supports repeat parcel packouts for refrigerated ingredients, ready meals, sauces and grocery orders.

Seafood, meat and poultry

Combines rigid insulation with optional liners and absorbent materials for chilled or frozen protein distribution.

Dairy and specialty food

Protects cheese, cultured products, confectionery ingredients and other temperature-sensitive foods during regional delivery.

Frozen food and desserts

Can be developed around frozen payloads and dry ice where ventilation, separation, labeling and transport rules are addressed.

Fresh produce and farm products

Helps reduce exposure to outdoor heat for berries, vegetables, premium fruit and other products that require a cool lane.

B2B samples and food-service supply

Provides a customizable format for product samples, test kitchens, distributors, restaurants and hospitality buyers.

How to plan the packout

Define the shipment profile

Confirm food type, payload dimensions and weight, target temperature, transit time, seasonal ambient exposure and delivery handoff.

Choose usable capacity

Allow space for the product, coolant, liner, absorbent material, dividers and void control before fixing the molded cavity.

Pre-condition the system

Chill or freeze the payload as required and condition gel, PCM or dry-ice refrigerant according to the approved packout plan.

Control moisture and contact

Use a watertight liner and absorbent layer when leakage or thawing is possible, and separate food from direct coolant contact.

Load coolant consistently

Place refrigerant in the tested positions, fill harmful voids and keep the product stable if the carton is handled in different orientations.

Fit the lid and close the carton

Install the EPS lid fully, apply the specified tape pattern and add perishable, orientation or dangerous-goods marks required for the route.

Validate the complete system

Test representative payload, coolant mass, ambient profile and handling before routine, long-distance or high-value shipments.

Customization support

Internal and external dimensions

Match the food packs, units per shipment, coolant clearance, courier limits and warehouse handling process.

EPS body and lid

Adjust wall thickness, foam density, lid fit, internal ribs, drainage features and molded cavities around the packout.

Thermal configuration

Select gel packs, PCM packs, ice bricks or dry ice and define conditioning, quantity, placement and product separation.

Moisture protection

Add product bags, a removable liner, absorbent pads or dividers for condensation, meltwater and leak control.

Carton strength and print

Specify board grade, closure, custom colors, logo, handling instructions, packout diagrams and required shipping marks.

Supply format

Plan samples, pilot quantities, bulk orders, nested carton packing and component staging for the buyer's fulfillment line.

Handling instructions

Store the corrugated cartons and EPS components in a clean, dry area. Before packing, inspect the molded body and lid for cracks, distortion or contamination and use only components approved for the packout.

Pre-condition the food and refrigerant according to the thermal plan. Install a watertight liner and absorbent material when condensation, thawing or liquid leakage is possible. Keep unpackaged food and freeze-sensitive products from direct contact with frozen coolant.

For chilled shipments, place conditioned gel, PCM or ice-brick coolant in the tested positions around the payload. For frozen shipments, use only the qualified refrigerant quantity and placement. Fit the EPS lid fully and close the corrugated carton with the specified tape pattern.

Dry ice releases carbon-dioxide gas. A dry-ice packout must not be airtight and requires suitable ventilation, product separation, handling protection, marking, documentation and current carrier acceptance.

The empty shipper does not create or guarantee a temperature duration. Performance depends on the payload, starting temperature, coolant mass, EPS wall thickness, ambient profile and handling. Validate representative shipments before routine use.

Features

  • Molded EPS body and fitted lid inside a corrugated shipping carton.
  • Custom usable capacity, foam thickness and coolant layout.
  • Chilled gel-pack and qualified frozen dry-ice configurations.
  • Optional liner, absorbent components and printed handling guidance.

Request packout support

  • Food type, package dimensions, weight and units per shipment
  • Chilled or frozen target condition and allowable temperature limits
  • Transit time, origin, destination and seasonal ambient exposure
  • Preferred usable capacity, outer parcel limits and EPS wall thickness
  • Gel, PCM, ice-brick or dry-ice refrigerant preference
  • Liner, absorbent, direct-contact and leakage-control requirements
  • Carton print, sample quantity, forecast volume and delivery schedule

FAQ

What does EPS-lined insulated shipping box mean?

It combines a molded expanded-polystyrene cooler and fitted lid with a protective corrugated shipping carton. The EPS provides insulation and shape, while the carton supports handling, closure, labeling and custom print.

How long can the box keep food chilled or frozen?

There is no single hold time for an empty box. Food mass, starting temperature, coolant type and quantity, foam thickness, ambient exposure and handling all affect performance. A 24–48-hour parcel route is a common development starting point, followed by testing of the complete packout.

What EPS wall thickness should I choose?

Many parcel projects begin around 25–50 mm. Short chilled lanes may use a thinner wall, while longer or more demanding routes may need thicker insulation and more refrigerant. Tempk selects the starting design after reviewing the shipment profile.

Should I use gel packs or dry ice?

Conditioned gel or PCM packs are commonly used for chilled products such as meal kits, dairy and seafood. Dry ice is normally considered for frozen products, but it needs ventilation, product separation, protective handling, marking and carrier approval.

Does the EPS cooler need an outer corrugated carton?

Yes for normal parcel distribution. The outer carton protects the molded foam, improves closure and stacking, and provides space for shipping labels and handling marks.

Can Tempk make custom sizes and printed cartons?

Yes. Tempk can adjust the molded inner cavity, wall thickness, foam density, carton strength, printing, liners, dividers and coolant layout, subject to tooling and order requirements.

Can the shipper be reused or recycled?

Reuse should only be considered when the carton and EPS remain clean, dry, undamaged and suitable for the approved packout. EPS collection and recycling acceptance vary by destination, so buyers should confirm local programs before making disposal claims.

Should the completed food packout be tested?

Yes. Testing with representative food, coolant quantity, starting condition, ambient exposure and handling is recommended before routine use, especially for frozen, long-distance or seasonal shipments.

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