High-Performance Insulated Shipping Boxes
48-72+ hours of protection for frozen and refrigerated shipments
PopupLiner™ – Trusted by leading brands. Engineered to outperform—and save space.
PopupLiner™ can keep your product frozen for up to 72 hours, outperforming all other insulated box liners on the market. One of the best-performing insulation materials available, PopupLiner™ is compact and features patented vacuum-compressed panels and a mylar shell that save warehouse space, reduce logistics costs, extend transit times, and deliver superior thermal performance—while also enhancing your customer's unboxing experience. Discover the next generation of temperature-controlled packaging solutions.
What makes PopupLiner™ the Best Insulated Box Liner Ever Made?
Engineered with patented vacuum-compressed panels and a reflective mylar shell, PopupLiner™ delivers unmatched thermal performance—and ships flat to save space and reduce freight costs.
- Top-Tier Thermal Performance
Outperforms traditional coolers and box liners in both hot and cold conditions in cold chain testing. Maintains target temperature longer and more reliably. - Custom Sizes
Standard sizes available or build your own. Add branding or custom specs to match your products and your message. - Frozen or Refrigerated? Works for Both
Whether you’re using insulated shipping boxes for frozen food—like ice cream, seafood, or meal kits— or aiming to keep products chilled, such as refrigerated medications, PopupLiner™ delivers consistent, reliable thermal protection.
- Ships Vacuum Compressed
IPC’s patented vacuum-compressed panels ship flat, saving you space and reducing freight costs. Open the liner bundle—panels pop up instantly, ready for use. Save warehouse space. Cut inbound freight. Speed up your packing lines. - Clean, Premium Presentation
No messy tape. No sloppy folds. PopupLiner™ expands into a crisp, structured box liner that enhances your customer’s unboxing experience.
The unique insulated box liners provide an alternative form of temperature-control packaging. They are made of a lightweight proprietary material that is both fully collapsible and compressed using our patented technology.
PopupLiner 2-Piece thermal box liners are constructed with flexible polyurethane foam insulators that are encased inside two metalized sleeves, designed to easily ‘lock’ together inside cartons of any size.
The padded, thermal box panels immediately turn any cold shipping box into custom-sized, temperature-control packaging that can be quickly loaded with temperature-sensitive goods and refrigerant products, such as refrigerant gel packs or dry ice.
This unique and innovative technology is patented. (Patent # US 8,333,279)
Unique Compression Technology
IPC’s innovative compression technology allows you to experience unparalleled cost savings on transport and warehousing.
LEARN MORE
PopupLiner insulated panels encased inside compression sleeve.
Compression sleeve keeps PopupLiner ultra-compact when in transit or storage.
Custom sizes and minimum order quantities
We specialize in manufacturing fully customizable sizes to fit your exact requirements at no additional cost. Get in touch to discuss your requirements.
The minimum order quantity for PopupLiner thermal liners is 1000 sets/pcs per size. Learn more about our minimum order quantities here.
How Does PopupLiner Work?
PopupLiner thermal box panels can be assembled in a matter of seconds.
Why PopupLiner?
Four reasons why PopupLiner Box Liners are your perfect insulated packaging solution.
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Effective for 48 to 72-hour shipments
PopupLiner thermal liners provides effective protection for transit durations of up to 72 hours.
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Unparalleled space efficiency
PopupLiner arrives compact, and will inflate to full thickness upon opening of the seal. This space-saving design, a patented feature, helps you to save on storage and warehousing costs.
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Environmentally friendly materials
Built with green, recyclable materials.
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Custom sizes
IPC prides itself on its ability to create custom-sized solutions, tailor made to fit the needs of the client.
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Increased Protection for Fragile Products
Products that are packaged using glass materials, like glass, need insulated shipping solutions that also provide a cushioning effect must be utilized in order to minimize and prevent movement. Any amount of movement, like dropping, shock and vibration, could result in damaged products.
Read more about the PopupLiner Insulated Box Liners.
High-performance, cost-saving insulated packaging
One of the most important benefits provided by our PopupLiner insulated shipping boxes is that they are highly space-efficient. While traditional temp-control packaging, such as molded containers, are bulky, our insulated box liners are sent to you collapsed and compressed. With 75% more space-efficiency than molded coolers, PopupLiner insulated boxes help you save substantially on warehousing and shipping costs.
This advanced space-efficiency feature helps IPC’s clients to receive industry-best pricing, made possible by the reduced inbound freight cost, as well as the labor savings achieved via reduced handling requirements.
This makes IPC’s PopupLiner insulated shipping boxes among the most cost-efficient substitutes for molded containers on the market today.
Compact and compressed form
PopupLiner cold shipping boxes are unique in that they provides extraordinary performance, while also arriving in a compact, easy-to-store form. The patent-pending technology provides unmatched efficiency of use in the packing area when compared to molded coolers. This compact storage feature allows more insulated box liners to be stored in a smaller area. Also, with less frequent replenishment required, workflow in the pack area is much more efficient.
PopupLiner panels are made of 100% recycled materials, and are themselves 100% recyclable.
IPC prides itself on being able to provide custom box sizes, and PopupLiner insulated containers are no exception.
Where does the high-performance come from?
It is all down to the high-performance insulating panel: Advanced Panel Filler.
PopupLiner’s super insulator panels are manufactured using a durable, impact-absorbing, and highly elastic foam that virtually stops heat flow due to its very low weight-to-volume ratio. The unique panels provide unmatched performance in the industry, while also extremely lightweight and flexible.
Millions of tiny capsules inside each foam panel act to slow down heat flow while remaining elastic and providing structure to the panel. The high-performance panel provides exceptional conductive insulation in addition to superb drop-testing performance.
Super reflective panel envelope
PopupLiner box insulation panels are encased in unique, completely enclosed radiant-barrier covers providing additional convective insulation. The carefully crafted outer envelope is designed specifically to work in combination with the foam filler. The unique structure provides the correct amount of convective heat resistance to augment the conductive insulation already presented by the advanced foam filler.
The envelope is carefully crafted to perfectly encase the panels, while allowing the necessary movement to facilitate a perfect fit inside the carton.
Shipping with dry ice
PopupLiner cold shipping boxes work particularly well when used in conjunction with dry ice. Load your temperature-sensitive items into a dry ice shipping container to further enhance its thermal performance, keeping your goods refrigerated for a longer period of time.
Custom sizes
IPC manufactures custom orders in-house, with low minimum requirements for any size of insulated container.
Also available: PopupLiner Ultra — the thicker walls provide extreme protection against cold and heat when placed inside an insulated shipping box, creating an Ultra High Performance insulated shipper.
Click here to read about why PopupLiner 3D insulation liners are better for the environment than polystyrene coolers.
PopupLiner panels: polyurethane foam insulators encased in metalized sleeves
Ice Cream inside a PopupLiner Insulated Box Liner
| Box Size: | 14″ × 14″ × 12″ |
| Insulator: | 2″ thick PopupLiner Box Liner |
| Commodity: | No payload |
| PCM Used: | 18 ºC (64.4 ºF) PCM pouches (weight: 8.25lb) |
| PCM Pre-Conditioning Temperature: | 15 ºC (59 ºF) |
| Temperature-Recording Device: | LogTag data logger |
| Payload: | 32oz. of vaccines |
| Vaccine Box Size: | 3.9” x 2.04” x 4.88” |
| Shipper Size: | 20” x 20” x 20” |
| Insulation Used: | 3” PopupLiner |
| Temp. Profile: | ISTA Summer 7D |
| Refrigerant Used: | 35 lbs. of dry ice |
| Transit Time: | 96 hour |
| Dry Ice Sublimation Rate: | 0.20 lb/h |
Research on the PopupLiner Box Liner
Alternative Insulation Solutions for Frozen Food Transportation [White Paper]
Enhanced Space Thermal Efficiency of Removable Thermal Box Liners [White Paper]
Freeze Protection of Water-Based Paint Using PopupLiner Box Liner [White Paper]
Modern Frozen Human Milk Shipping Using Passive Insulation System [White Paper]
Insulated Packaging for Reusable Containers Using PopupLiner Thermal Box Liner [White Paper]
Maintaining Controlled Room Temperature and 5 °C for Pharmaceuticals [Case Study]
Expanding Reach for Mail-Order Beef Companies While Boosting Profitability [Case Study]
How to Ship Refrigerated Products with PopupLiner [Resource]
Related Products
All our products are developed and manufactured from our factory in the USA.
Ready to impress your customers and simplify your cold chain with our insulated box liners?
Join the growing list of brands shipping confidently with PopupLiner™.
