Which cold chain packaging you need depends on four things: how cold your product must stay, how long it is in transit, under which conditions it travels, and how large the shipment is. With those four answers, you choose the right combination of box, insulation, and coolant in a few minutes. This guide walks you through step by step — including ready-made example combinations per sector.
Cooled Solutions has been a Dutch producer of cold chain packaging since 1972. We think along with you instead of just selling products: the packaging must be right — not too light, and not unnecessarily expensive.
- Which temperature? Frozen, chilled (2–8 °C), cool, or protected from heat.
- How long in transit? From a few hours to several days.
- Under which conditions? Summer or winter, small package or pallet.
- Which material fits? EPS, EPP, honeycomb or thermal pallet cover — plus the right coolant.
Step 1 — Determine your temperature zone
First determine within which temperature limits your product must remain. This determines both the coolant and the amount of insulation you need.
| Zone | Temperature | Typical products | Appropriate coolant |
|---|---|---|---|
| Frozen | below -18 °C | ice, frozen meat and fish, deep-frozen pharma | dry ice or large 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 | single gel packs or PCM, especially good insulation |
| Protected (CRT) | 15–25 °C | products that must not get warm, room-controlled pharma | insulation + PCM at room temperature |
Unsure between two zones? Choose the strictest (coldest) requirement — that way you’re always safe.
Step 2 — Estimate your transit time
The time between shipping and arrival determines how much cooling and insulation is needed. Always calculate with 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-layer or EPP + PCM packs + data logger |
| 72+ hours | Custom solution — have the performance validated | Combination on advice, with temperature validation |
Step 3 — Consider environment and size
Season and outdoor temperature
A shipment standing for hours on a warm loading dock in summer needs more cooling than the same shipment in winter. At high outdoor temperatures or 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 — which works to your advantage, but large boxes also lose more heat through their walls. For small packages, 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 | Light | Recyclable | Fish, meat, food, and pharma — most shipments |
| EPP | Excellent | Light and strong | Reusable | Return logistics and high-quality pharma |
| Honeycomb cardboard | Good | Light | Fully paper-recyclable | E-commerce and sustainable shipments |
| Thermal pallet covers & film | Good (reflective) | Very light | Reusable | Pallets, air freight, and large loads |
The workhorses. Thin wall for lightly cooled transport, thick wall for long or severe cooling, with or without drainage holes (for fish and ice).
Ready-made insulated boxes. 4-layer for medium transit, 6-layer for the heaviest cooling and freezing requirements.
EPP for reusable, robust solutions. Honeycomb for a plastic-free, neat appearance that can be fully recycled with paper waste.
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 | Note |
|---|---|---|---|
| Gelpacks / ice packs | 0 °C | chilled shipments (2–8 °C) | fully pre-frozen |
| Ice Pack Sheets | 0 °C | flat cooling, meal boxes, e-commerce | flexible, easy to place |
| Reusable gel packs | 0 °C | return systems, frequent shipments | intake/return logistics needed |
| PCM-packs | adjustable (e.g. +5, +21 or -20 °C) | pharma and long transit — stable temperature | pre-condition at the correct temperature |
| Dry ice | -78 °C | deep freeze and very long transit | safety, ventilation and air freight regulations (on advice) |
Rule of thumb: more coolant for longer transit time, higher outside temperature and a lighter box. For a chilled shipment up to 24 hours in a well-insulated box, 2 to 3 gelpacks are often sufficient; for 48–72 hours or in summer, scale this up or switch to PCM. The exact amount depends on your product — preferably validate a new setup once with a datalogger. Shipping fish, meat or moist products? Then add an absorption mat against leakage.
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. Mostly EPS + gelpacks, often with absorption mat.
View selection →GDP-compliant solutions with PCM and datalogger for 2–8 °C and room-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-pack, neat and scalable solutions — honeycomb or EPS with ice pack sheets.
View selection →Example combinations
For inspiration — proven combinations our customers use daily. Adjust them to your transit time and season.
EPS box with thick wall + 2–3 gelpacks + absorption mat against leakage.
Honeycomb or EPS thin wall + ice pack sheets. Neat, fully recyclable appearance.
EPS box with leak holes + ample ice packs, so meltwater can drain away.
Thermal box 6-layer of EPP + PCM +5 °C + datalogger. GDP-compliant.
EPS with thick walls + ample ice packs, or dry ice on advice from our specialists.
Thermal cover over the pallet + insulation film. IATA-compliant for long transit.
Checklist before you order
- Temperature zone determined (deep freeze / chilled / cool / protected)
- Longest realistic transit time estimated, including delays
- Season and waiting times considered
- Insulation material and box size chosen
- Sufficient coolant, pre-conditioned
- When in doubt: validate the setup once with a data logger
Our advisors will help you choose the right combination and, if desired, send samples or a trial setup. Advice is free and without obligation.
Request advice or a quoteor call +31 (0) 255 234 200For large batches and regular customers
As a Dutch manufacturer, we supply not only individual packages but also structural solutions for companies shipping on a larger scale:
Competitive bulk prices from larger orders, and annual contracts with fixed rates for regular customers.
Production in the Netherlands and custom sizes on order, with short lines and delivery times of 2–4 weeks.
Your own branding on the box, or delivered completely neutral — ideal for distributors.
On pallets, on call, within agreed windows — and if desired, 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. Learn more about the options for suppliers and distributors or request a quote directly.
Want to know more? Check out the frequently asked questions or the glossary with explanations of commonly used terms.