Expansion Foam Insulated Mailers with a cold ice pack and pharmaceutical products getting ready to inside
Three white insulated foam expansion mailer sleeves of varying sizes stacked diagonally against a transparent background, each featuring blue branding text that reads "PERISHABLE" alongside an address label grid on the front.

EXPANSION FOAM INSULATED MAILERS

Foam Expansion Insulated Mailers

Insulated Foam Mailers provide lightweight thermal protection and form-fitting cushioning for small temperature-sensitive shipments. Self-expanding memory foam inflates around the payload to reduce excess air space, improve frozen gel pack cooling efficiency, and protect contents from crushing during transit. Easy to use, simply load with frozen gel packs, seal with the adhesive strip, pierce to inflate, and ship. Ideal for biotech, medical, food, and specialty perishables, these compact, cost-effective mailers reduce material usage and can be recycled into carpet padding where programs exist.

  • Form-Fitting Cushioning: Expands around the payload to provide reliable crush protection.
  • Compact Shipments: Eliminates excess interior air space to optimize cooling efficiency.
  • Fast Packout Process: A fast,  practical process; load, seal, pierce to inflate, and ship.
  • Space-saving
  • No outer box required

  • Life Sciences: Small biotech shipments, test kits, clinical samples, and medical products.
  • Perishables: Small-batch gourmet foods, specialty goods, and temperature-sensitive product samples.
  • Specialty Shipping: Compact payloads requiring a balance of thermal insulation and integrated shock absorption.

These mailers offer an ideal, cost-effective alternative when a payload’s size or transit window does not require a rigid insulated shipping container, yet still demands dependable thermal protection and cushioning.

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Insulated Foam Mailers
Item Number Item Dimensions Qty. per Case Case per Pallet
KM-1911-2 9 x 11 in. expanding 1 in. envelope 72 32
KM-2911-2 9 x 11 in. expanding 1 3/8 in. envelope 72 32
KM-11214-2 12 x 14 in. expanding 1 in. envelope 48 32
KM-21214-2 12 x 14 in. expanding 1 3/8 in. envelope 48 32
KM-11418-2 14 x 18 in. expanding 1 in. envelope 24 30
KM-21418-2 14 x 18 in. expanding 1 3/8 in. envelope 24 30

Free Shipping and handling within the United States.

Does not include accessorial service fees. Prices are subject to change without notice.

Note: Lead time 2-3 business days. Pallet Order(s) 2-3 weeks

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Frequently Asked Questions

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How do insulated foam mailers protect products during transit?

The expanding foam creates a form-fitting cushion around the product, reducing open air space inside the package. Less internal air space gives frozen gel packs a smaller area to cool, while the cushioning structure adds crush protection during handling and transit.

Are insulated foam mailers a replacement for EPS or urethane containers?

No. Insulated foam mailers are best for smaller, short-duration shipments where lightweight protection and compact packouts matter. EPS foam containers and urethane insulated containers are better suited for larger payloads, longer transit windows, frozen shipments, or products with tighter temperature tolerances.

Do insulated foam mailers reduce shipping costs?

Insulated foam mailers reduce material volume, lower dimensional weight (DIM weight) charges, and cut freight costs compared to bulkier, rigid packaging formats.

Should temperature indicators or data loggers be used with insulated foam mailers?

For high-stakes shipments, yes. Temperature Indicators provide a clear visual signal when a threshold is breached, while data loggers provide a timestamped record of the shipment’s temperature history. Operators shipping regulated, high-value, or temperature-sensitive products should match the monitoring device to the risk level of the payload.

Guaranteed Temperature Integrity for Every Mile.

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