1. First Liner
The first PenguinPak liner is placed into the box.
Upto 72 Hours thermal protection
Paper-based thermal insulation made from recovered fibre
Sustainable paper based insulation liners, manufactured in the UK, that keep your products chilled, frozen or warm throughout their entire journey.
2. Second Liner
A second liner is added around the three remaining sides of the box. The box is ready to be packed!
3. Products in
Pack the box as you normally would with fresh or frozen goods, plus your ice or cool packs to bring the temperature down.
4. Sealed & Shipped
Fold the PenguinPak lid over your goods, then close and securely seal the box, minimising any air gaps where possible. Add your shipping label and dispatch to your customer via your usual 48-hour courier service.
Recovered Fibre Insulation Core
Recycled fibres trap air and help slow temperature transfer.
Paper Outer Layers
Tear-resistant paper forms the outer surface of the liners. This can be supplied with a water-resistant layer for added protection when packing condensation-prone products. We can also print your logo directly onto the surface.
Whole liner secured with glue
Inside of liner glued and sealed around the edges to safely secure the fluffy fibres in place.
Sustainable by design
Made from paper and recycled cardboard, PenguinPak is designed with circularity in mind.
- Paper outer layers
- Insulating core from waste paper & card
Proven thermal capabilities
Reliable thermal insulation designed to maintain temperature of your products from “store to door”.
- Independently tested
- Effective trapped-air insulation
Easy for your customers
Simple, practical packaging that’s easy for your customers to unpack, reuse and recycle.
- Simple to recycle
- Simple, mess-free unpacking
- Easy to reuse or repurpose
Versatile by design
Flexible insulated liners tailored to suit different products, box sizes and temperature requirements.
- Custom-made to your boxes
- Suitable across multiple industries
- Fresh, chilled or frozen
Compared with Expanded Polystyrene (EPS)
PenguinPak offers a flexible, paper-based alternative to bulky expanded polystyrene (EPS) packaging. Designed to fit your existing boxes, the liners are easy to store and can be recycled in most household kerbside paper collections.
A customer tested PenguinPak in Half Euro and 2 Stone boxes against an EPS box.
The results show PenguinPak matched or outperformed EPS for thermal performance.
| Feature | PenguinPak | EPS Box |
|---|---|---|
| Frozen protection | ||
| Paper based construction | ||
| Kerbside recyclable options | ||
| Custom sizes | Limited | |
| Lower plastic complexity |
Thermal Results Comparison
Performance results from our real world testing.
- Polystyrene Box
- Half Euro Box
- 2 Stone Box
Pack loaded
Frozen contents packed inside the thermal liner and outer box.
Frozen Maintained
Internal readings remain within the target cold-chain range.
Stable hold
Temperature remains controlled through the main delivery window.
Critical point
Highlight the point most buyers care about for shipment protection.
Test complete
Final data logged and available inside the full technical report.
Ideal for many applications
Frozen & Chilled
Seafood
Designed for fish, shellfish and seafood boxes where temperature control, moisture resistance and odour-conscious packaging matter.
- Frozen fish deliveries
- Chilled seafood boxes
Butchers & Food producers
Meat & Poultry
Suitable for chilled and frozen meat and poultry sent through courier, direct-to-consumer.
- Chilled or frozen meat or poultry
Meal Delivery
Frozen Meals
For prepared meals, recipe boxes and frozen food deliveries where customers expect simple disposal and reliable arrival condition.
- Ready meals
- Meal kits
- Subscription boxes
Controlled logistics
Pharmaceuticals
For temperature-sensitive healthcare products where packaging needs can be discussed against specific temperature and transit requirements.
- Healthcare samples
- Pharmaceutical products
Small & Large Boxes
Pet Food
Suitable for fresh, chilled and frozen pet food sent through courier, direct-to-consumer.
- Fresh & chilled pet food
- Frozen pet food
Cushioning
Fragile Goods
The recovered fibre core can also provide a protective cushioning layer for glassware, ceramics and high-value items.
- Void fill
- Protective wrap
- Plastic reduction
Bespoke Packaging
Packaging Merchants
A flexible option for merchants and distributors who need variable liner sizes, thicknesses and application-specific specifications.
- Bespoke dimensions
- Variable thickness
- Outer box pairing
Circular by design
PenguinPak insulation liners are manufactured in the UK, alongside our parent company, Limehouse Board Mills. We know exactly what materials are used to make the liners and recycle waste paper and card from our own factory operations to make the fluff fibre which forms the insulation properties. At the end of their journey, the liners can be recycled again.
For more information on where your liners are made, please visit the Limehouse Board Mills website.
Ready to rethink insulated packaging?
Whether you’re a meal-kit provider, pharmaceutical distributor or packaging merchant, PenguinPak can help you reduce environmental impact without compromising on performance.
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