EPS box alternatives: cardboard, EPP or thermal box
An EPS box alternative comes in three forms: EPP, a cardboard cooler box and a thermal box with an insulated bag. Below you find the data of each alternative side by side.
EPS box alternatives: the options side by side
If you are looking for a foam alternative or a styrofoam alternative, there are EPP, cardboard cooler boxes and thermal boxes. Styrofoam is another name for EPS, and Tempex is the older brand name.
| Option | Use | Strong points | Note |
|---|---|---|---|
| EPS box | Shipping chilled and frozen | Light, shock-resistant, directly from stock | The wall thickness decides the cooling time |
| EPP box | Reusable | Shock-resistant, 100% recyclable, many transport cycles | Reuse needs a return process |
| Cardboard cooler box (honeycomb) | Paper recycling | 100% paper, sturdy, delivered flat, printable | Outer size and build differ from EPS |
| Thermal box with insulated bag | Small to large shipments | Delivered flat, up to 5 times more on a pallet than EPS | Separate bag and box when disposing |
EPS or EPP: two reusable materials
EPS boxes are foam: light and well insulating, in thin-walled and thick-walled versions. An EPP box is shock-resistant and meant for shipping temperature-sensitive products many times over. It can withstand many transport cycles without losing its insulating effect.
The EPP range includes an EPP box of 425 x 345 x 305 mm (24 liters, wall 30 mm) and an EPP box of 600 x 400 x 300 mm (42 liters, wall 35 mm). Both are meant for companies that regularly ship chilled and want to reduce their waste streams. Combine them, as with EPS, with gel packs on top of the product and a box that is filled as well as possible.
EPP and EPS: the sizes side by side
The EPP box is made of Expanded Polypropylene, the EPS boxes of 100% polystyrene. Below, two EPP boxes next to an EPS box.
| Box | Outer size | Inner size | Wall thickness | Per pallet |
|---|---|---|---|---|
| EPP 24 liters | 425 x 345 x 305 mm | 365 x 285 x 235 mm | 30 mm | 42 pieces |
| EPP 42 liters | 600 x 400 x 300 mm | 530 x 330 x 230 mm | 35 mm | 35 pieces |
| EPS 30 liters | 600 x 400 x 300 mm | 500 x 300 x 200 mm | 50 mm | 35 pieces |
The EPP box of 42 liters and the EPS box of 30 liters have the same outer size and fit 35 pieces on a pallet. The EPS box has a 50 mm wall versus 35 mm, and the EPP box has 42 instead of 30 liters of volume. An EPS box is delivered including a matching lid.
Plastic-free cooler box: cardboard honeycomb
If you want to ship without foam, a plastic-free cooler box made of cardboard comes closest. The honeycomb insulated box has the insulation in the wall itself: honeycomb cardboard and corrugated cardboard, entirely paper. The hexagonal air chambers hold still air, the same principle as with foam. The insulation value is comparable to EPS. The box is extra strong and stackable, is delivered flat and goes into paper recycling after use. With the right cooling elements you bridge 24 to 48 hours in transit. Take a look at the honeycomb cooler boxes and the cardboard cooler boxes. A detailed comparison is in EPS boxes vs honeycomb cooler boxes.
Insulated box and Eco Coolbox: two other cardboard builds
The insulated box is a corrugated cardboard outer box including 2 Isoliners, paper insulation sheets that line the bottom, walls and top of the inside. There are three sizes: S (250 x 250 x 250 mm), M (300 x 300 x 300 mm) and L (355 x 355 x 355 mm). The box is delivered flat, the outside is fully printable and the insulation value is, according to the product data, comparable to EPS. The Isoliner sheets can be ordered separately: 42 sheets for 21 boxes for S and M, 36 sheets for 18 boxes for L.
The Eco Coolbox is a pre-formed box of pressed, recycled cardboard with the insulation in the wall. The product data call the insulating effect at least comparable to an EPS box. The collection gives a thermal conductivity coefficient of λ = 0.036 W/(m·K) and mentions at least 24 hours of transport time with dry ice.
| Eco Coolbox | Volume | Wall thickness |
|---|---|---|
| 315 x 235 x 265 mm | 8.9 liters | 2.9 cm |
| 400 x 300 x 300 mm | 18.2 liters | 2.9 cm |
| 600 x 400 x 375 mm | 49.8 liters | 4 cm |
Empty, the Eco Coolbox of 400 x 300 x 300 mm weighs 1.6 kg (maximum load 15 kg), and the one of 600 x 400 x 375 mm weighs 3.7 kg (load 25 kg).
Thermal box as an alternative when space and pallet capacity matter
A foldable thermal box consists of a cardboard box with a separate insulated bag. The bag is bubble wrap with a metallized coating and the box goes into paper recycling. The advantage is storage: the box is delivered flat, so up to 5 times more fits on a pallet than with EPS. A thermal box holds temperature for up to 48 hours (suitable from -20 °C to 25 °C). The volume runs from approx. 12 liters (300 x 200 x 200 mm) to approx. 96 liters (600 x 400 x 400 mm), and the insulated bag can also be reordered separately. The number of layers of the bag determines the insulation value: four layers is the standard choice for chilled transport and shorter to medium transit times, and for longer trips, warm weather or deep freeze you choose more layers. See also insulated shipping bags. If you are choosing between a thermal box and EPS, read thermal box or EPS box.
Which wall thickness you choose determines the cooling time, and the outside temperature, filling and cooling elements count as well. You can read more about the environmental side in is EPS bad for the environment.
Frequently asked questions about an EPS box alternative
What is the difference between EPS and EPP?
EPS is expanded polystyrene, EPP is expanded polypropylene. An EPP box can withstand many transport cycles without losing its insulating effect and is 100% recyclable.
Is there a foam alternative without plastic?
Yes, the cardboard honeycomb cooler box consists entirely of paper and is recyclable.
Can I reuse an EPP box?
Yes. The EPP box is reusable and meant for shipping temperature-sensitive products many times over.
What is an Isoliner insulation sheet?
A flat, pre-folded paper insulation lining that is placed in a cardboard box. Unfolded, the sheet lines the complete inside: the bottom, the four walls and the top. After use the sheet goes into paper recycling.
Unsure which foam alternative suits you? Send us your route, quantities and return expectation, and we will think along with you. If you want to see the standard first, take a look at our EPS boxes, from our own production since 1972, available directly from stock.
You will find all names in our glossary.
