AerVault® is a ready to use mailer designed for rugged protection of cold chain payload. They are lightweight, space-efficient thermal protection for small to medium temperature-sensitive shipments. Designed to help maintain consistent internal temperatures during transit, AerVault combines insulated performance, recyclable materials, and convenient peel-and-seal closure in a compact vacuum compressed for storage.
The only certified curbside recyclable, paper liner rated for 72-hour refrigerated shipping. Unlike cellulose liners that require special handling, CelluLiner™ goes straight into your recycling bin—nationwide. Experience true satisfaction with insulation that actually gets recycled and proven to keep your products cold.
AerVault® Mailers are designed for businesses that need dependable thermal protection without the weight and bulk of traditional insulated shipping containers.
The mailers use multi-layer insulation with microscopic air pockets to slow thermal exchange and help maintain consistent internal temperatures during transit. A recyclable outer material provides durability and a clean, professional appearance, while the integrated peel-and-seal adhesive strip allows products to be packed and secured quickly.
AerVault is particularly well suited for small to medium shipments of temperature-sensitive products, including pharmaceuticals, diagnostic samples, prepared foods, chocolates, supplements, and other specialty products.
AerVault® Mailers reduce freight volume and storage requirements for more efficient handling and shipping. Their lightweight construction can also help lower transportation costs.
The mailers feature a recyclable polyester exterior designed to support more sustainable packaging initiatives. This gives businesses a thermal shipping solution that balances performance with environmental considerations.
A simple packing process makes AerVault® Mailers easy to prepare for shipment. The integrated tape-lip closure provides a secure way to close the mailer without adding complicated assembly steps.
The self-expanding design provides cushioning around the shipment while helping absorb impact during handling and transportation. This adds another layer of protection for products moving through the shipping environment.
AerVault® Mailers are available in standard sizes designed for efficient, temperature-controlled shipping. Choose the size and insulation configuration that best fits your application.
Standard Sizes
Insulation
Thickness
Thermal Performance
Closure
Exterior Material
MOQ
1″ AerVault® Pouch Size 12″ X 14″
1″ AerVault® Pouch Size 9″ X 11″
1.5″ AerVault® Pouch Size 9″ X 11″
1.5″ AerVault® Pouch Size 12″ X 14″
Flexible Polyurethane Foam
1.0″ or 1.5″
Up to 48 hours
Tape-lip closure
Recyclable Polyethylene
2,000 pcs per size
Need a configuration beyond our standard sizes? AerVault® Mailers can be customized to better fit your products, shipping requirements, and branding needs.
CUSTOM SIZING
Explore sizes beyond our standard 9″×11″ and 12″×14″ formats.
INSULATION OPTIONS
Discuss the appropriate insulation configuration for your needs.
BRANDING
Ask about branding and custom requirements.
Tell us about your product, shipment, and application. Our team can help determine the right configuration.
Proven Performance in Real-World Cold-Chain Conditions
AerVault® Mailers are engineered to provide reliable thermal protection for temperature-sensitive shipments. In-house testing helps demonstrate how the mailer performs under controlled temperature conditions and supports its use for short-duration cold chain applications.
48 HOURS
34°C
0%
Maintained between 2–8°C
Peak ambient temperature
Deviation above 5°C
Product
Profile
Coolant
Payload
Target range
Pre-condition
AerVault™ 1″ × 12″ × 14″ mailer
ISTA 7E Summer (35-hour qualification; graph through hour 36)
4 × 24 oz + 1 × 6 oz frozen gel packs
22 × 10 mL water-filled vials in a carton
1–8 °C for 35 hours
Mailer and vials at 1–5 °C for ≥24 hours
| Configuration | Min | Max | Avg | Result |
|---|---|---|---|---|
|
Chamber ambient (0–36 h) |
24.3 °C |
31.1 °C |
27.7 °C |
— |
|
Content |
0.8 °C |
8.0 °C |
2.1 °C |
PASS |
Insulated shipper
Payload
Refrigerant
Pre-conditioning
AerVault™ 1″ × 12″ × 14″ self-expanding insulated mailer
22 × 10 mL vials filled with water and packed in an internal carton
4 × 24 oz and 1 × 6 oz frozen gel packs surrounding the payload carton
Mailer and all water-filled vials held at 1–5 °C for at least 24 hours before packout
Result: PASS. The AerVault 12 × 14 configuration passed IPC’s 35-hour evaluation. The 1-inch AerVault payload first exceeded 8 °C at hour 34.74.
AerVault® Mailers are designed for fast, straightforward packing. Simply open the mailer, place the temperature-sensitive products and appropriate refrigerant inside, then secure the closure before shipping.
Open the pre-compressed AerVault Mailer and puncture the outer envelope to allow the foam inner insulation to expand.
Place temperature-sensitive products and the appropriate refrigerant inside.
Close the mailer and secure the integrated peel-and-seal closure.
Apply the shipping label to the sealed mailer and prepare it for shipment.
AerVault Mailers are designed for short- to mid-duration temperature-sensitive shipments, with IPC materials identifying the product for approximately 24–48 hours of thermal protection. Actual performance depends on shipment conditions, product load, refrigerant, ambient temperature, and configuration.
Standard AerVault sizes include 9 × 11 inches and 12 × 14 inches. Contact IPC to discuss your specific product dimensions and packaging requirements.
AerVault is designed with recyclable outer material. If recyclability is a primary requirement for your program, IPC can help identify the appropriate packaging configuration.
Yes. AerVault Mailers are delivered in a compressed format to help reduce storage volume and improve warehouse handling efficiency.
AerVault is suited for small to medium temperature-sensitive shipments, including pharmaceuticals, diagnostic samples, prepared foods, chocolates, supplements, and specialty products.
IPC’s current page references branding and customization discussions. The exact options should be confirmed with the IPC team based on size, volume, and application.
Tell us about your product, shipment requirements, and temperature range. Our team can help you determine the right insulated packaging solution for your application.
A reusable insulated pouch engineered for up to 48 hours of thermal protection, featuring dual tape and resealable zip closures for secure, convenient shipping. Available in standard sizes with 1.0" or 1.5" foam insulation.
High-performance refrigerant packs designed to help maintain cold temperatures throughout transit. Available in a variety of sizes and configurations for pharmaceuticals, food, and other temperature-sensitive shipments.
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