A packaging assembly includes an outer box including a first main panel connected to a second main panel, a third main panel connected to the second main panel, and a fourth main panel connected to the third main panel, the fourth main panel connected to the first main panel; an insert, an insert connected to at least two of the main panels of the outer box, the insert including a first main panel connected to a second main panel; a third main panel connected to the second main panel; and a fourth main panel connected to the first main panel and the third main panel, wherein at least one support formation is arranged between at two of the four main panels, wherein each support formation connects the insert to the outer box.

A method for insulating a box includes positioning an insulated panel adjacent to a side panel of the box, the insulated panel including an insulation batt and a sheet, the insulated panel defining a border extending around a perimeter of the insulation batt; and attaching a seam of the border to a portion of a perimeter area of the side panel.

An insulated packaging assembly can include a box having a plurality of sides and a bottom; a liner defining an interior cavity and having a plurality of sides defined by a plurality of end panels; a liner top positioned within the interior cavity of the liner; and at least one separation feature connected to the side of the liner between the side of the liner and the corresponding side of the box; wherein each end of each end panel defines a protrusion tab, and a first separation feature of the at least one separation feature can include a protrusion tab of one of the end panels extending beyond an outer surface of an adjacent end panel.

A box is made by folding a sheet of material. Preferably, the box is formed by applying adhesive and folding using a machine, and a waterproof or water resistant coating is applied so that the box is configured for use as a cooler. The box includes (a) a storage portion, including a bottom panel, a first end panel, a second end panel, a first side panel, and a second side panel; (b) four corner panels; (c) a top panel including tabs; and (d) a latching panel attached to the first side panel and pivotable relative thereto about a fold line, the latching panel including first and second subpanels. The latching panel includes cuts extending between and dividing the first and second subpanels through which the tabs respectively extend when the cooler is in a closed position.

A blank to form an insert connected to an outer box, the blank including a first side; a second side positioned opposite the first side; a first main panel adjacent to a first support formation; a second main panel adjacent to the first support formation; a third main panel adjacent to the second main panel; a second support formation adjacent to the third main panel; a fourth main panel adjacent to the second support formation; and a connection panel adjacent to the fourth main panel.

A shipping assembly for transporting refrigerated items includes an outer box defining an outer box cavity, a bottom insulator box assembly received in the outer box cavity superposed above the bottom panel, an insulated inner box positioned in the outer box cavity above the bottom insulated box assembly, the insulated inner box defining a ridge and an inner box cavity, wherein ridge panels and retention flaps of the outer box engage end panels of the insulated inner box such that the insulated inner box is retained in a position spaced from outer box side panels, with an insulation wrap occupying the space between the insulated inner box and the outer box walls. A top insulator box assembly is partially received in the inner box cavity, such that overhang portions of a top panel of the top insulator box assembly rest upon the ridge of the insulated inner box.