eFoodsDirect is one of the many online names in the U.K. that offer halal meat delivery across the country. Religious and dietary perspectives aside, the company, like its competitors, analyzed an opportunity that a particular group of people in the country only buys halal meat, even if it meant travelling to other cities because of low availability.
But meat, whether halal or not, is extremely perishable and very sensitive to environmental conditions. Devising a supply chain strategy that ensures that the products reach the customer fresh and safe is literally the cornerstone of the entire business idea.
This is where cold supply chains come in.
While the technology is far from new, its ever-increasing deployment and technological updates have made it an important point of discussion. And as demand for temperature-sensitive shipping grows, so does the need for packaging that can keep up. It&rsquo;s not just about getting products from point A to point B. It&rsquo;s about making sure they arrive safe, stable, and uncompromised, regardless of the environmental conditions.
Apart from fresh food items, pharmaceuticals, biotechnology, electronics, craft beverages, and chemical industries, all depend on cold supply chains and, by extension, insulated shipping boxes that meet the budget, are durable, protect the items from environmental impacts, and protect the environment from businesses&rsquo; carbon footprints.
<a href="https://themailerbox.com/Blog/corrugated-boxes-for-industry-comparing-the-strength-of-single-double-and-triple-walled-designs/">Corrugated boxes</a>, a type of paper packaging with additional insulation layers, meet all of the above criteria. Such custom packaging is engineered with insulation, moisture protection, and structural durability to support the unique challenges of cold chain logistics.
In this article, we explore how the cold supply chain is growing and the role of custom packaging in supporting this growth.
<h2>Cold Chain Packaging for Food and Pharma</h2>
Standard style packaging stops being enough when the products become more and more specialized. A few years ago, who would&rsquo;ve thought that fresh meat could be ordered from another city to be delivered directly to the consumer?
Specialized custom packaging has its application in several industries with temperature control requirements. The table below selects and notes down the key requirements of three of these:
<table width="0">
<tbody>
<tr>
<td width="156">
Industry
</td>
<td width="156">
Products
</td>
<td width="156">
Temperature Needed
</td>
<td width="156">
Packaging Needs
</td>
</tr>
<tr>
<td width="156">
Frozen Food
</td>
<td width="156">
Frozen/fresh meats, frozen meals, Frozen desserts etc.
</td>
<td width="156">
-20&deg;C to 4&deg;C
</td>
<td width="156">
Insulated corrugated boxes with moisture control
</td>
</tr>
<tr>
<td width="156">
Pharmaceuticals
</td>
<td width="156">
Vaccines, biologics
</td>
<td width="156">
-70&deg;C to 8&deg;C
</td>
<td width="156">
Compliance-ready packaging
</td>
</tr>
<tr>
<td width="156">
Grocery
</td>
<td width="156">
Meal kits, fresh produce
</td>
<td width="156">
0&deg;C to 10&deg;C
</td>
<td width="156">
Lightweight recyclable materials
</td>
</tr>
</tbody>
</table>
Before going into the technicalities of custom packaging boxes for each of these, let&rsquo;s have a look at the markets for each category:
<h3>Frozen Food</h3>
The frozen and fresh food market is booming. In 2024, the global cold chain packaging market for perishable foods was estimated at USD 30.2 billion and is expected to reach USD 74.4 billion by 2033, with nearly 10% annual growth (Precedence Research, 2025). The reason behind the growth is the rising demand for seafood, meal kits, dairy, and organic food. Temperature range, humidity, and delivery duration are considerations you must make when you choose your corrugated boxes.
<h3>Pharmaceuticals</h3>
The global pharmaceutical cold chain packaging industry reached USD 17.5 billion in 2024 and is anticipated to grow over fourfold by 2034 at a compound annual growth rate (CAGR) of ~15% (Global Market Insights Inc., 2025). The majority of this growth can be factored through the rise of mRNA vaccines, biologics, and cell therapies. For example, the size of the vaccine shipping market alone, a critical subset of the cold chain, was estimated at USD 1.2 billion in 2023 and is projected to grow to USD 2.5 billion by 2032.
Along with maintaining the temperature in warehouse houses, vehicles, and storage rooms, packaging fragile and perishable pharmaceutical products is also a highly critical requirement of the cold supply chain.
<h3>Grocery Delivery</h3>
Regular grocery delivery has surged in demand, and so has the necessary packaging that supports that channel. This home delivery surge is driving higher demand for insulated corrugated boxes that can safeguard products throughout last-mile delivery. It forms part of a global cold chain market worth more than USD 365 billion in 2024 and forecast to be more than USD 1.4 trillion by 2034 (IMARC, 2025).
<h2>Functionality and Innovation of Insulated Shipping Boxes</h2>
Insulated shipping boxes are created using multiple layers, each serving a separate purpose: protecting, containing, and/or presenting the contents.
The outer layer is typically a corrugated boxboard, which provides strength and facilitates stacking. The second layer provides thermal insulation and is manufactured with materials such as reflective bubble wrap or Expanded Polystyrene (EPS) Foam. Some liners include phase change materials or gel packs for added control.
Not every cold chain shipment needs the same insulation. Meal kits or fresh produce might require shorter duration cooling than mRNA vaccines. The table below presents insulation types with their key features and industrial uses:
<table width="0">
<tbody>
<tr>
<td width="156">
Liner Type
</td>
<td width="86">
Thermal Efficiency
</td>
<td width="109">
Recyclability
</td>
<td width="273">
Common Use Case
</td>
</tr>
<tr>
<td width="156">
PMC-based systems
</td>
<td width="86">
Very high
</td>
<td width="109">
Varies
</td>
<td width="273">
Biologics, mRNA vaccines. High-risk pharma shipments use thicker paper liners with PCM inserts to maintain low temperatures for several days.
</td>
</tr>
<tr>
<td width="156">
Bubble foil liner
</td>
<td width="86">
Medium
</td>
<td width="109">
Partially
</td>
<td width="273">
Grocery, short-distance shipments. They provide easy insertion and curbside recyclability.
</td>
</tr>
<tr>
<td width="156">
EPS foam inserts
</td>
<td width="86">
High
</td>
<td width="109">
Low
</td>
<td width="273">
Frozen food, seafood.
Shipping boxes typically use hybrid liners combined with gel packs or dry ice.
</td>
</tr>
</tbody>
</table>
It should go without saying, but we&rsquo;ll still emphasize it: any thermal insulation must not compromise the box&rsquo;s durability and appearance.
<h3>Custom Packaging, Cold Supply Chain, and Sustainability Goals</h3>
As mentioned, the insulated shipping boxes market is expanding rapidly. According to the stats published by Credence Research Inc. (2025), this market was valued at USD 6.1 billion in 2024 with an expected compound annual growth rate of 5.4%. This is because insulated&nbsp;<a href="https://themailerbox.com/corrugated-boxes/">corrugated boxes</a>&nbsp;are not just a technique for product containment and logistics, but rather a critical tool for regulatory compliance, sustainability efforts, and, most importantly, to protect and deliver the promised value to the end consumer.
<h3>Eco-Friendliness of Insulated Shipping Boxes</h3>
On one hand, the demand market size and demand are increasing, but on the other, the need to reduce landfills and minimize carbon footprints is also increasingly becoming a baseline regulatory requirement.
Paper-based custom packaging is generally considered one of the most optimized packaging options that brings together eco-friendliness, structural integrity, aesthetic presentation and durability. When it comes to engineering corrugated boxes with environmental control, achieving all of the above with the same effectiveness becomes a little challenging.
Innovators in packaging-related technology are constantly working towards achieving 100% recycled and recyclable materials; however, at the moment, not all custom packaging insulations are eco-friendly.
For example, Polystyrene, a.k.a Styrofoam, is a commonly used but non-recyclable packaging insulator that is as frequently used for temperature control as it is for impact protection. Polystyrene-related waste has persisted in landfills, but no other material has effectively been able to mimic its capabilities enough for it to be substituted entirely.
Eco-friendly alternatives include insulators made from plant-based materials or regenerated textiles that either decompose naturally or are curbside recyclable. While this transition to greener alternatives is underway, achieving sustainable-only insulated shipping boxes worldwide remains an ongoing process.
<h3>Testing Custom Packaging for Cold Supply Chain</h3>
The fragility and perishability of the cold chain&rsquo;s contents make it vital for their packaging to be quality assured. A number of standards exist to test and validate the quality of insulated&nbsp;<a href="https://thevyvymanga.com/customized-boxes-can-reduce-your-shipping-costs-learn-how-to-optimize-your-packaging-to-increase-profitability/" target="_blank" rel="noopener">shipping boxes</a>. These include:
<ul>
<li>NF S99-700 (AFNOR):&nbsp;Focused on healthcare product packaging through 21 temperature control profiles.</li>
<li>ASTM D3103-07:&nbsp;Focused on thermal qualification of insulated packaging.</li>
<li>International Safe Transit Association (ISTA Standards): a series of procedures to test packaging performance, including drop test, compression tests, and vibration tests, among others.</li>
</ul>
Packaging quality assurance looks at the structural integrity and durability, regulatory compliance and product-specific performance of packaging. The primary goal of such performance testing is to protect the products from degradation or spoilage.
<h4>Checklist: What to Look for in Cold Chain Packaging</h4>
Before choosing a packaging supplier, ask:
<ul>
<li>What&rsquo;s the expected transit time and temperature range? </li>
<li>Is the insulation material rated for this use case? </li>
<li>Does the system comply with food or pharma safety standards? </li>
<li>Can any part of the packaging be reused or recycled? </li>
<li>Is the third-party pre-test or validation done on the packaging?</li>
</ul>
Is the third-party pre-test or validation done on the packaging?
This type of planning makes your corrugated boxes do more than just ship goods.
<h4>Conclusion</h4>
As the cold chain increases in food, pharma, and grocery stores, packaging is more than merely a barrier. It impacts the quality, safety, and consumer confidence of the product. Whether you are shipping frozen meals, vaccines, or fresh fruit, the proper corrugated box, particularly when insulated with the correct material, is the formula for delivering it in top condition.
Insulated shipping box technology is assisting companies like yours in meeting these changing demands. With increasing performance needs, regulation, sustainability, and single-use packaging will continue to be necessary.
If you&rsquo;re looking to upgrade the packaging of your cold chain or would like a suggestion on the most suitable insulated corrugated box for your product, contact&nbsp;<a href="https://themailerbox.com/">The Mailer Box</a>&nbsp;today. They have experts who are well-versed in state-of-the-art, dependable packaging products that comply with industry standards and surpass expectations.
References
<ol>
<li><a href="https://www.precedenceresearch.com/cold-chain-market" target="_blank" rel="noopener">https://www.precedenceresearch.com/cold-chain-market</a></li>
<li><a href="https://www.gminsights.com/industry-analysis/pharmaceutical-cold-chain-packaging-market" target="_blank" rel="noopener">https://www.gminsights.com/industry-analysis/pharmaceutical-cold-chain-packaging-market</a></li>
<li><a href="https://www.imarcgroup.com/cold-chain-packaging-market" target="_blank" rel="noopener">https://www.imarcgroup.com/cold-chain-packaging-market</a></li>
<li><a href="https://www.credenceresearch.com/report/insulated-corrugated-boxes-market" target="_blank" rel="noopener">https://www.credenceresearch.com/report/insulated-corrugated-boxes-market</a></li>
</ol>

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