Insulated thermal pallet cover: good protection for temperature-sensitive goods
Short answer: an insulating thermal pallet cover is a multi-layer cover (aluminium reflective layer + bubble film) that fits over a complete pallet and helps keep the temperature of the load stable for hours, against heat in trucks and cold on the tarmac. It is reusable, fitted in seconds and can be combined with cooling elements for longer journeys. Note that this is not the same as a plastic pallet cover against rain or dust. A thermal cover insulates against temperature.
When you want to transport complete pallets of temperature-sensitive products, there is always a risk that the load becomes too warm or too cold along the way. An insulating thermal cover is an effective solution for minimising these risks.
What is a thermal cover for pallets?
An insulating thermal cover is a large, made-to-measure cover that is placed over a complete pallet. The cover is built up from several layers of insulation material, including aluminium reflective layers and bubble film. This combination keeps the temperature inside the pallet stable, regardless of external conditions.
What are the applications?
- Shipping of frozen or chilled foodstuffs
- Pharmaceutical pallet transport
- Flowers and plants over long distances
- Air freight shipments on ULDs and pallets
Benefits of a thermal cover
- Protects against extreme heat (such as in trucks in summer)
- Protects against cold (such as on the tarmac at airports)
- Easy to use: simply place it over the load
- Reusable across multiple shipments
- Can be combined with cooling elements for longer transports
How do the layers work together?
The aluminium outer layer reflects part of the radiant heat, for example from the sun on a platform. The bubble film contains air and slows heat transfer between outside and inside. Together they slow down the temperature change of the load. The cover does not produce cold itself. It mainly slows warming up or cooling down.
How to fit the cover correctly
- Build the pallet neatly. An even pallet lets the cover close properly.
- Secure the load with film or straps before you fit the cover.
- Check the starting temperature. A cover holds temperature, it does not restore a warm load.
- Pull the cover over the entire pallet, including the top.
- Close any gaps. Open seams and loose corners let heat through.
Which size of cover do you need?
Measure the pallet including the load: length, width and height. Also include the height of the top layer and any protruding boxes. If the cover is too tight, it will not close properly. If it is too loose, air forms between the cover and the load. Made-to-measure solutions are possible for non-standard sizes, such as a ULD or a tall pallet. See also our page on thermal covers for pallets.
How long does a cover hold the temperature?
That depends on the outside temperature, the sun, the starting temperature of the load, the mass of the load and any cooling elements. We therefore do not quote a fixed time. If you want to know what happens in your supply chain, place a data logger in the pallet and measure your route once. You can find data loggers in our collection data loggers. More background can be found in our article how long does a thermal cover keep the load at temperature.
Thermal cover or active cooling?
For short journeys and transfer moments, a cover may be enough. For long journeys with a strict temperature regime, you will often choose active cooling. Read the comparison in thermal cover or refrigerated truck.
Questions to ask yourself before you order
- How long will the pallet stand outside a chilled area at most?
- What temperature must the load maintain, and what is the margin?
- Will the cover come back, so that you can use it again?
- Do you need extra cooling elements in the pallet?
- Is the pallet going by air? Then also take a look at our range for air freight.
Maintenance and reuse
Check the cover for tears and loose seams after every trip. Store it dry and folded. A damaged reflective layer works less well, so replace the cover in good time.
Common mistakes
- Fitting the cover on a pallet that has already warmed up.
- Not covering the top, even though that is where most heat enters.
- Using a cover that does not match the pallet dimensions.
- Not adding cooling elements on long journeys or in warm weather.
Frequently asked questions
Is a thermal cover the same as a plastic pallet cover? No. An ordinary pallet cover protects against rain and dust. A thermal cover has insulating and reflective layers for temperature protection.
Can I use the cover several times? Yes, the cover is reusable. How often depends on the use and the care with which you handle it.
Does a cover also fit over a ULD or roll container? Standard and made-to-measure sizes are available for this. Send us the dimensions and we will advise you.
Should I add cooling elements? For longer journeys or warm weather, that is advisable. The cover slows the warming up, the cooling elements provide the buffer.
At Cooled Solutions you will find insulating covers in standard and made-to-measure versions. Please get in touch for advice on the right solution for your transport.
Order directly
Need the right packaging straight away? Take a look at our thermal covers, container liners and insulation film.
