A temperature controller shipper for shipping temperature sensitive products. A plurality of individual product boxes contained in an inner mastercase each include a lyophilized product with low thermal mass. The plurality of product boxes each contain a unique PCM thermal dunnage insert occupying the normally empty space within the product box. The PCM insert artificially increases the thermal mass within each product box, and the added thermal mass enables an outer volume of thermal material, e.g. a PCM bladder or bricks, to be minimized to reduce the overall shipper volume and weight.

An insulation wrap includes an insulation batt defining a top end and a bottom end, the insulation batt defining an inner side and an outer side; a wrap liner blank including an inner portion extending across a first panel and a second panel of the wrap liner blank, the inner side of the insulation batt positioned facing the inner portion; a ledge portion extending across the first panel and the second panel of the wrap liner blank, the ledge portion hingedly coupled to the inner portion by an inner hinge, the top end of the insulation batt positioned facing the ledge portion; and an outer portion extending across the first panel and the second panel of the wrap liner blank, the outer portion hingedly coupled to the ledge portion by a ledge hinge.

Provided is an insulation liner for use inside a shipping carton that affords thermal insulation and shock absorption for an object to be shipped, a liner and carton system, a method of production of the insulation liner, and methods of use. The insulation liner includes a larger component folded into three panels, a smaller component folded into three panels, and standoffs disposed on the surfaces of both the larger component and the smaller component. The standoffs may be oriented inwardly or outwardly. When oriented outwardly they create an interstitial air space that reduces conduction allowing the insulation effect of the liner and carton system to equal or exceed that of a molded polystyrene container of an equal size.

A container for transporting materials in a temperature-controlled manner.

An insulation wrap includes an insulation batt defining a top end and a bottom end, the insulation batt defining an inner side and an outer side; a wrap liner blank including an inner portion extending across a first panel and a second panel of the wrap liner blank, the inner side of the insulation batt positioned facing the inner portion; a ledge portion extending across the first panel and the second panel of the wrap liner blank, the ledge portion hingedly coupled to the inner portion by an inner hinge, the top end of the insulation batt positioned facing the ledge portion; and an outer portion extending across the first panel and the second panel of the wrap liner blank, the outer portion hingedly coupled to the ledge portion by a ledge hinge.

An insulation wrap includes an insulation batt defining a top end and a bottom end, the insulation batt defining an inner side and an outer side; a wrap liner blank including an inner portion extending across a first panel and a second panel of the wrap liner blank, the inner side of the insulation batt positioned facing the inner portion; a ledge portion extending across the first panel and the second panel of the wrap liner blank, the ledge portion hingedly coupled to the inner portion by an inner hinge, the top end of the insulation batt positioned facing the ledge portion; and an outer portion extending across the first panel and the second panel of the wrap liner blank, the outer portion hingedly coupled to the ledge portion by a ledge hinge.

An insulated packaging assembly can include a box including a top side wall, a bottom side wall, a first lateral side wall, a second lateral side wall, a third lateral side wall, and a fourth lateral side wall, the box defining a cavity; a first thermal liner positioned in the cavity, a first portion of the first thermal liner positioned in contact with the top side wall, a second portion of the first thermal liner positioned in contact with the first lateral side wall, a third portion of the first thermal liner positioned in contact with the bottom side wall; and a second thermal liner positioned in the cavity, a first portion of the second thermal liner positioned in contact with the second lateral side wall, a second portion of the second thermal liner positioned in contact with the third lateral side wall.

A packaging may include at least one insulating wall and at least one cooling device embedded into the at least one wall. A method of forming at least one insulating wall of a package may include placing a cooling device into a form, closing the form, injecting a liquid form of an expansive foam, and curing the foam.

A method of collapsing a box from an expanded configuration to a collapsed configuration is disclosed. The method of collapsing a box from an expanded configuration to a collapsed configuration, the box comprising a side panel and a bottom panel attached to the side panel, can comprise bending a center fold line of the side panel; unbending a length fold line defined between the side panel and the bottom panel; bending a first corner fold line that extends from a bottom panel corner of the bottom panel to an edge fold line of a center subpanel of the bottom panel; and bending a second corner fold line that extends from the bottom panel corner to a longitudinal center line that bisects a bottom panel edge of the bottom panel.

A thermal insulation article for placement in a shipping container to hold an item includes a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover one or more of a floor, four side walls and cover of the container while leaving an interior space to receive the item. The thermally insulating pad includes a compostable panel that holds together as a single unit and is formed primarily of starch, and compostable or recyclable film forming a pocket and surrounding the panel to prevent water from reaching the panel within the pocket. The film is secured to the panel along a portion but not all of the opposite surfaces of the compostable panel.