Large polystyrene box: 28 to 173 litres and which size fits
Short answer: our large polystyrene boxes range from 28 to 173 litres. Between 57 and 173 litres we have no standard size. If you need 80 to 100 litres, choose either the 57-litre box (possibly two units) or the 173-litre box, depending on your product. It's about the internal dimensions, not the external dimensions.
When most people talk about a large foam box, they mean a box from approximately 30 litres. The term is not standardised. In this article you will find all larger formats from our range with internal dimensions, wall thickness and quantity per pallet. All sizes come from our product descriptions. Our polystyrene boxes have been made in-house since 1972.
Large polystyrene boxes in brief: from 28 to 173 litres
| Capacity | External dimensions (mm) | Internal dimensions (mm) | Wall thickness (mm) | Per pallet | Product page |
|---|---|---|---|---|---|
| 28 L | 595 x 400 x 173 | 550 x 352 x 143 | 27,5 | 60 | Polystyrene box 28 L, 595x400x173 |
| 28 L | 550 x 380 x 230 | 490 x 320 x 180 | 30 | 60 | Polystyrene box 28 L, 550x380x230 |
| 29 L | 690 x 360 x 188 | 640 x 310 x 145 | 22,5 | 60 | Polystyrene box 29 L, 690x360x188 |
| 30 L | 600 x 400 x 300 | 500 x 300 x 200 | 50 | 35 | Polystyrene box 30 L, 600x400x300 |
| 31 L | 600 x 400 x 208 | 550 x 350 x 160 | 25 | 60 | Polystyrene box 31 L, 600x400x208 |
| 34 L | 600 x 400 x 205 | 540 x 340 x 165 | 30 | 60 | Polystyrene box 34 L, 600x400x205 |
| 42 L | 600 x 400 x 270 | 550 x 350 x 220 | 25 | 45 | Polystyrene box 42 L, 600x400x270 |
| 45 L | 600 x 400 x 400 | 500 x 300 x 300 | 50 | 25 | Polystyrene box 45 L, 600x400x400 |
| 57 L | 605 x 405 x 350 | 545 x 345 x 300 | 30 | 30 | Polystyrene box 57 L, 605x405x350 |
| 173 L | 800 x 600 x 650 | 680 x 480 x 530 | 60 | 6 | Polystyrene box 173 L, 800x600x650 |
All dimensions in mm (L x W x H). The internal dimension is the space you can actually use. Products with "pallet" in the name are delivered per full pallet. The 30, 34, 42, 45 and 57 litre boxes can be ordered from 1 unit, with tiered pricing. Smaller sizes up to 27 litres can be found in the collection.
What the large sizes are suitable for
According to our product descriptions, these polystyrene boxes are suitable for chilled or frozen shipments of food, medicines and other temperature-sensitive products. The 30 and 45 litre boxes have a 50 mm wall and are designed for longer shipping routes. The 28 litre box of 595 x 400 x 173 mm is suitable for large products, the one of 550 x 380 x 230 mm has more height. The 29 litre box has an elongated format. The 34 litre box is also available without drainage holes according to the description. The 173 litre box is designed for bulk shipment of large quantities of chilled products.
Is there a polystyrene box of 80, 100 or 200 litres?
No. Our sizes go from 57 to 173 litres. For 100 litres, choose two 57-litre boxes or the 173-litre box with extra filling. You can do this:
- Need 80 to 100 litres? Choose the 57-litre box and split your shipment across two boxes (total 114 litres of internal space). If your product per unit doesn't fit in 57 litres, the 173-litre box is the only larger option. Fill the extra space well.
- Need 200 litres? Our largest box is 173 litres. For more volume, distribute the load across multiple boxes.
- Many boxes at once? We deliver sizes from 28 to 31 litres per pallet of 60 units. This is convenient if you ship large quantities.
Are you unsure between two sizes? Contact us with the dimensions of your product. Then we can help you decide.
External dimensions, internal dimensions and capacity: how to read the dimensions
A polystyrene box has thick walls. Because of this, the capacity in litres is much less than the volume of the external dimensions. The litre designation from our product descriptions is the volume of the internal space. Therefore always calculate with the internal dimensions. You need the external dimensions for pallet, storage and outer box.
| Box | External volume | Internal capacity | Wall thickness |
|---|---|---|---|
| 42 L, 600 x 400 x 270 mm | 64.8 litres | 42 litres | 25 mm |
| 45 L, 600 x 400 x 400 mm | 96 litres | 45 litres | 50 mm |
| 173 L, 800 x 600 x 650 mm | 312 litres | 173 litres | 60 mm |
We calculated the external volume ourselves (L x W x H). Also look at the wall thickness. The 42-litre box is 30 mm lower on the outside than the 30-litre box, yet it has more capacity. The wall is 25 mm instead of 50 mm. A thicker wall insulates longer and takes up internal space. Read more about this in how long does a polystyrene box stay cold.
Choose the right size in four steps
- Measure your product including any inner packaging.
- Add the space for cooling elements. A 400-gram gel pack is approximately 12 x 21 cm.
- Compare with the internal dimensions in the table and choose the smallest box that fits everything.
- Choose the wall thickness based on travel time. For short routes, a thin wall is often sufficient, from 24 hours you choose a thick wall.
A half-empty box warms up faster than a full box. So prefer the smallest size that fits everything. All rules can be found in choosing the right box size.
How many cooling elements do you need in a large box?
In our article about gel packs, we mention as a rule of thumb 1 gel pack of 400 grams per 5 to 8 litres of capacity for a chilled shipment of 24 hours. For 48 hours, that's two, and for frozen shipments you double the number. That rule applies to boxes up to 20 litres.
If you calculate this for the 42-litre box, you would need approximately 5 to 8 gel packs of 400 grams for 24 hours. This is just a starting point for large boxes. Place a data logger in the box with your first shipment and monitor the temperature curve. That way you know exactly how much space you have. The full calculation method can be found in how many gel packs do you need per shipment. Matching gel packs can be found in the collection.
Polystyrene box with lid and outer box
A matching lid is always included. This is stated in the product descriptions for these sizes. For the 30, 34 and 45 litre boxes, a suitable cardboard outer box is available for extra strength during transport.
Frequently asked questions about large polystyrene boxes
Is there a polystyrene box of 100 litres?
No. Our sizes go from 57 to 173 litres. For 100 litres, choose two 57-litre boxes or the 173-litre box with extra padding.
What is the largest polystyrene box?
The 173-litre box. External dimensions 800 x 600 x 650 mm, internal dimensions 680 x 480 x 530 mm, wall thickness 60 mm. It is delivered per pallet of 6 units.
How many litres really fit in a box?
Look at the internal dimensions. The thick walls take up a lot of space. For example, a box of 600 x 400 x 400 mm has 96 litres of external volume, but 45 litres of capacity.
How thick should the wall be?
Thick-walled (30 to 50 mm) insulates approximately two to three times longer than thin-walled (20 mm). For routes from 24 hours, you choose a thick wall.
Can I also order a large box per unit?
Yes, the 30, 34, 42, 45 and 57 litre boxes can be ordered from 1 unit. We deliver the other sizes in the overview per full pallet.
Choose the size that fits your shipment
View all sizes, from small to 173 litres, under buy polystyrene boxes. Order today before 14:00 and we will ship the same day.
