Metallic Insulated Mailers And Puncture Packs

Our Insulated Metallic Mailers are engineered for high-performance cold chain protection with space-saving, user-friendly design. These mailers feature vacuum-sealed insulation that remains compressed during storage and shipping — and expand instantly when activated by the user via a simple peel-and-seal sticker.

Key Product Features
  • Vacuum-Sealed Foam Insulation: Internal thermal foam is compressed and sealed for ultra-efficient storage
  • Peel-to-Inflate Activation: Simply pull the adhesive tab to allow the mailer to expand before packing
  • Zipper Lock + Peel-and-Seal Strip: Dual closure system for security and tamper evidence
  • Up to 4x Expansion: Inflates to full thickness from vacuum-packed form in seconds
  • High-Performance Materials: Built for 24–72 hour thermal protection
  • No Outer Box Required: Rigid structure eliminates need for secondary packaging in most cases
metallic mailer

Insulated Mailer Vacuum Technology Explained

Unlike traditional insulated packaging, these mailers ship with the foam insulation vacuum-sealed inside each pouch. This:

  • Reduces pre-use volume by up to 75%
  • Makes storage and shipping far more efficient
  • Enables on-demand expansion with a peel tab

How it works:

  • The insulation inside the mailer is compressed and vacuum-sealed at the factory.
  • When ready to use, the customer pulls the peel tab, releasing the seal.
  • The mailer expands automatically to its full foam thickness in a few seconds.
  • Product is inserted, zipper closed, and peel-and-seal strip pressed to lock.

Insulated Mailer Sizes

Mailer Size Common Use Cases
7″ x 11″
Single vials, test kits, insulin
9″ x 12″
Cosmetics, vaccines, small pouches
10″ x 14″
Frozen meals, diagnostic kits
12″ x 16″
Multi-item shipments, sample boxes
14″ x 18″
Medium medical kits, perishables
15″ x 20″
Large biologics, subscription boxes

Custom sizes available on request

Insulated Mailer Foam Thickness Options

Foam Thickness (Each Side) Total Wall Thickness Ideal Use Duration
1/2″
1″
Short transit (<24 hrs)
3/4″
1 1/2″
Medium (24–36 hrs)
1″
2″
Standard (36–48 hrs)
1 3/8″
2 3/4″
Extended (48 hrs)

All insulation is vacuum-sealed and expands upon activation

Insulated Mailer MATERIAL COMPOSITION

Outer Layer:

0.12mm Metallic Foil – Reflects Radiant Heat

Insulation:

28 kg/m³ Polyurethane (PU) Foam – Vacuum-sealed for space savings

Inner Layer:

0.07mm White Polyethylene (PE) – Clean, durable, and food-safe

Total Wall Thickness:

Up to 2.75 inches depending on configuration

Inflation Mechanism:

Pull tab breaks vacuum seal and expands insulation instantly

Smarter cold chain starts here

Request a free sample, download the spec sheet, or contact us for a custom quote tailored to your product.

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