PopupLiner 2-Piece Insulated Box Liner

Formerly known as GreenLiner, this high-performance, environmentally friendly and space-efficient box liner is perfect for shipments of more than 48 hours.

insulated box liner

PopupLiner 2-Piece thermal box liners are high-performance box insulation liners recommended for shipments of 48 hour or longer of refrigerated or frozen goods.

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.

insulated Box Liner
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.

"The best performing insulation we have found."

"Inch for inch, the performance is unmatched."

How Does PopupLiner Work?

PopupLiner thermal box panels can be assembled in a matter of seconds.

Insulated Containers
Insulated Box Liners

Video Demonstration

Watch the video below to see how easy and quick it is to use PopupLiner insulation.

Why PopupLiner?

Four reasons why PopupLiner Box Liners are your perfect insulated packaging solution.

  • Effective for 48 to 72-hour shipments

    PopupLiner thermal liners provides effective protection for transit durations of up to 72 hours.

  • 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.

  • Environmentally friendly materials

    Built with green, recyclable materials.

  • Custom sizes

    IPC prides itself on its ability to create custom-sized solutions, tailor made to fit the needs of the client.

  • 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

Performance Testing

We have performed the below tests to ensure the efficacy of our insulated shipping boxes 

2 – 8 °C Performance over 36 Hours (Pharmaceuticals)

Details: 0.5lbs of Red Blood Cell Reagants
Box Size: 15.5″ x 13.5″ x 9.5″
Container Used: Carton lined with PopupLiner Box Liner
Pre-Shipment Temp: 5 °C (41 °F)
Refrigerant Used: 6x 300g PCMs & 4 24oz gel packs
Temp. Profile: ISTA Summer 7E

Dry Ice Consumption Rate

Details: No payload
Insulator: 3″ PopupLiner
Box Size: 20″ x 20″ x 20″
Container Used: Carton lined with PopupLiner Box Liner
Refrigerant Used: 35lbs of Dry Ice
Temp. Profile ISTA Summer 7D
Dry Ice Weight Loss Rate: 0.29 lb/h = 6.96 lb/day

60-Hour CRT (15-20ºC) Performance

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

96-hour Frozen Vaccine Shipment Performance

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

Related Products

PopupLiner Box Liners

PopupLiner Insulated Box Liners have an advanced space-saving design in that they are shipped compressed and automatically expand to full size when opened, resulting in unparalleled space-efficiency and cost savings.

Paper Insulated Box Liners

CelluLiner Insulated Box Liners are made entirely of curbside-recyclable materials and provide effective temperature control for 48 hours. With a 100% paper construction, CelluLiner box liners protect shipments against even the most extreme ambient conditions.

All our products are developed and manufactured from our factory in the USA.

Want to know more about our Insulated Box Liners?

Call us, we are here to help:

310 638 0900