A modular box assembly includes a box having a top end, an opposed bottom end, and side panels extending from the top end to the bottom end. A bottom panel is disposed at the bottom end such that the side panels and the bottom panel define a box cavity and the top end defines a box opening. A shoulder is attached to two side panel and extends inward from the side panels into the box cavity, wherein each shoulder is spaced from the top end a predetermined distance. A box top covers the box opening, the box top being selectively movable about and between a closed position and an open position. In the closed position, the top panel engages the shoulders to support the top panel, and in the closed position an upper surface of the top panel is substantially flush with the top end of the box.

A shipping container includes a plurality of thermally insulating pads positioned in a cavity in a box. Each pad of the plurality of thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate, and a recyclable film formed primarily of paper. The recyclable film forms a pocket enclosing the panel. The panel is loose within the pocket. At least one of the plurality of thermally insulating pads includes a multi-section panel including a score across its width in at least one location. The score extends partially, but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent.

A shipping container includes a plurality of thermally insulating pads positioned in a cavity in a box. Each pad of the plurality of thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate, and a recyclable film formed primarily of paper. The recyclable film forms a pocket enclosing the panel. The panel is loose within the pocket. At least one of the plurality of thermally insulating pads includes a multi-section panel including a score across its width in at least one location. The score extends partially, but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent.

A packaging may include at least one insulative wall and at least one cooling device embedded into the at least one wall. A method of forming at least one insulative 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 cooler to hold an item includes a solid compostable or recyclable body that is primarily plant fiber. The body includes a floor and a plurality of side walls that are coupled to the floor along first common edges and each coupled to two adjacent side walls along second common edge. The floor and the plurality of side walls define an interior space of the body to receive the item and an opening to the interior space. The body is at least inch thick.

Shipping container systems are provided for shipping a temperature sensitive product or payload. The systems include at least one heat transfer element and a payload container configured to hold payload therein and configured to be positioned within a shipping container; the payload container being spaced from sidewalls of the shipping container. Also included are spacers that may for example, space the payload container from one or more of the heat transfer elements. The spacers are configured to allow air to flow over surfaces of the payload container and heat transfer elements. Also included are kits that include components of the system and methods. Further provided are products that include any one or more of the described elements; and fully assembled shipping containers.

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 insulative insert for a shipping container includes at least one insulative pad and an inner layer. The at least one insulative pad is formed from fibers of a first material having a first strength. The first material includes at least one of cellulose and synthetic polymer. The inner layer is formed from a second material having a second strength that is greater than the first strength. The inner layer is joined to the at least one insulative pad to form the insulative insert. The insulative insert is configured to lie flat in an unfolded position and to form a cube shape in a folded position.

An insulation liner includes an outer film; and an insulation material encapsulated within the outer film. An insulation packaging assembly includes a box defining a box cavity; a first insulation liner positioned within the box cavity, the first insulation liner defining a C-shape, the first insulation liner including an outer film and an insulation material encapsulated within the outer film; and a second insulation liner positioned within the box cavity, the second insulation liner defining the C-shape, the second insulation liner fitting together with the first insulation liner to define a storage cavity enclosed by the first insulation liner and the second insulation liner.

A nested insulated packaging assembly comprising an outer box and a thermal liner. The outer box includes an outer top side wall, an outer bottom side wall, and a plurality of outer lateral side walls. The thermal liner includes a terminal top end, a bend line, a top fold defined between the terminal top end and the bend line, and a back fold. The top fold is foldable relative to the back fold at the bend line. The back fold contacts one of the outer lateral side walls of the outer box. The thermal liner includes a thermal control material extending across the bend line.