Comparison of Novel Materials For Thermal Packaging Solutions in Cold Chain Logistics. (24.08)

Comparison of novel materials for thermal packaging
solutions in cold chain logistics.
Master Thesis
For the degree of
Master of Science in Engineering (MSc)
by University of Applied Sciences - FH Campus Wien

Master Program:
Packaging Technology and Sustainability
Author:
Benjamin Smits
Personal identification number: C1910844026
Supervisor:
Farshad Sharbafian
Date:
14. 08. 2023
Declaration of Originality:
I declare that this master thesis was written by myself and that I did not use any other than
the mentioned remedies or did not use any other unauthorized help.
I assure that I have not submitted this master thesis in any form either in Austria or abroad
(to a reviewer) as an examination paper.
Furthermore, I assure that the copies submitted by me (printed and electronically) are
identical.
14/08/2023
Date: ........................................ Signature: ............................................................................
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I. Abstract
This master thesis investigates a number novel thermal packaging materials, derived
from wool, hemp and recycled paper and compares their performance with a conventionally
available expanded polystyrene (EPS) solution. Novel packaging solutions have been
acquired from several different providers as well as identically sized postage boxes in order
to undertake a series of experiments to determine how novel materials compare to
conventional products. Thermal performance of the novel packaging materials have been
compared to EPS in order to assess their potential for use in the delivery of temperature
sensitive products directly to the end consumer. Experiments involved the time-temperature
analysis of food-substitute products and coolants inside cardboard boxes lined with various
insulation materials. The results show that recycled paper has a comparable or better
thermal performance characteristics to EPS and in some instances outperform EPS as an
insulation material. It can be concluded that low-cost , lightweight, biodegradable packaging
materials have the potential to replace conventional EPS insulation materials with those that
are sustainable, circular and are derived from materials that are inherently renewable.
II. Key Words
Chilled; food safety; cold-chain; novel solutions; heat transfer of packages; thermal insulation;
temperature controlled packaging.
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III. Table of Contents
I. Abstract 2
II. Key words 2
III. Table of Contents 3
IV. List of Abbreviations 5
IV. List of Figures and Tables 6
1.0. Introduction 8
2.0. Aim and Research Question 11
3.0. Literature Review 12

3.1. Part 1 - A Brief History of Temperature Controlled Packaging 12
3.2. Part 2 - Logistics of Temperature Sensitive Products 15
3.2.1. Importance of Packaging in Cold Chain Logistics 15
3.2.2. Food Products 16
3.2.3. Food Waste 17
3.2.4. Food Safety Issues 17
3.2.5. Non - Food Products 18
3.2.6. Non - Food Waste 18
3.2.7. Non - Food Safety Issues 19
3.2.8. Phase Change Materials 19
3.3. Part 3 - Conventional Cold Chain Packaging Material 20
3.3.1. Expanded Polystyrene Inlays 20
3.3.2. Environmental Considerations of Conventional Packaging Material 20
3.3.3 Advantages and Disadvantages of Conventional Packaging Material 22
3.4. Part 4 - Novel Cold Chain Packaging Materials 23
3.4.1. Novel Packaging Materials 23
3.4.2. Environmental Considerations of Novel Packaging Materials 24
3.4.3. Advantages and Disadvantages of Novel Packaging Material 27
4.0. Materials 28
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5.0. Method 39
5.1. R - Value of Insulating Packaging Materials 39
5.2. Melting Point of Phase Change Materials 40
5.3. Latent Heat and Heat Absorption of Phase Change materials 41
5.4. Temperature Monitoring with Phase Change Materials 41
5.5. Temperature Monitoring without Phase Change Materials 42
5.6. Water Vapor Transmission Rate of Novel Packaging Material 42
5.7. Monitored Delivery 43
6.0. Results 45
6.3. Latent Heat and Heat Absorption of Phase Change Materials 52
7.0. Discussion 74
7.3. Latent Heat and Heat Absorption of Phase Change Materials 78
8.0. Conclusion 86
9.0. References 88
10.0. Appendix 1 - Detailed Results 95
4
IV. List of Abbreviations
CE - Circular economy
CO2 eq. - Carbon dioxide equivalent
EC - European Commission
EOL - End of life
EPS - Expanded polystyrene
EU - European Union
GDP - Good distribution practices
GHG - Greenhouse gas
HDPE - High density polyethylene
LCA - Life cycle assessment
MSW - Municipal solid waste
PC - Post consumer
PCM - Phase change material
PLA - Polylactic Acid
PE - Polyethylene
PET - Polyethylene terephthalate
PS - Polystyrene
RH - Ralative humidity
UV - Ultra violet
WHO - World Health Organisation
WVTR - Water Vapor Transmission Rate
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V. List of Figures and Tables
Figure 1: Optimal Packaging 15

Figure 2: Fields of Application of Plastic Materials and Polymer Types
Predominately used in Packaging 21
Figure 3: Distribution of Plastic Applications in Consumption and
Waste in the European Union 21
Figure 4: Opportunities for Material Efficiency 25
Figure 5: Circular Economy Systems Diagram 26
Figure 6: EPS inlays inside Postal Box 28
Figure 7: EPS Inlay 29
Figure 8: Supaso Ecoliner (Without Top Cushion) Inserted into Post Box 30
Figure 9: Supaso Ecoliner 31
Figure 10: Internal Contents of Supaso Ecoliner 31
Figure 11: Landpack Landbox Hemp (Without Top and Bottom Liner)
inserted into post box 32
Figure 12: Landpack Landbox Hemp Liner 33
Figure 13: Internal Contents of Landpack Landbox Hemp Liner 33
Figure 14: Woolcool Fleece Liner (Without Top and Bottom Liner)
Inserted into Post Box 34
Figure 15: Woolcool fleece liner 35
Figure 16: Internal Contents of Woolcool Fleece Liner 35
Figure 17: Österreich Post AG Paket Box Large 36
Figure 18: Tive Tag Temperature Logger (Front and Rear) 37
Figure 19: Supaso Frozen Ice Pack 38
Figure 20: Coolways Kraft Paper Gel pack 38
Figure 21: Package Experiment Assembly 44
Figure 22: Melting Point of PCMs in EPS Inlays 46
Figure 23: Melting Point of PCMs in Landpack Landbox Hemp 47
Figure 24: Melting Point of PCMs in Woolcool Fleece Liner 48
Figure 25: Melting Point of PCMs in Supaso Ecoliner 49
Figure 26: Melting Point of PCMs Comparison 50
Figure 27: Latent Heat Experiment Results - Average 52
Figure 28: 24 hour Temperature Monitoring with PCMs - EPS Inlays 54
Figure 29: 24 hour Temperature Monitoring with PCMs - Landpack
Landbox Hemp 55
Figure 30: 24 hour Temperature Monitoring with PCMs - Woolcool
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Fleece Liner 56
Figure 31: 24 hour Temperature Monitoring with PCMs - Supaso Ecoliner 57
Figure 32: 24 hour Temperature Monitoring with PCMs - Interior Insulating
Material Comparison 58
Figure 33: 24 hour Temperature Monitoring with PCMs - Package Comparison 59
Figure 34: 24 hour Temperature Monitoring without PCMs - EPS Inlays 61
Figure 35: 24 hour Temperature Monitoring without PCMs - Landpack
Landbox Hemp 62
Figure 36: 24 hour Temperature Monitoring without PCMs - Woolcool
Fleece Liner 63
Figure 37: 24 hour Temperature Monitoring without PCMs - Supaso Ecoliner 64
Figure 38: 24 hour Temperature Monitoring without PCMs - Interior
Insulating Material Comparison 65
Figure 39: 24 hour Temperature Monitoring without PCMs - Package
Comparison 66
Figure 40: Temperature Profiles EPS Inlays 69
Figure 41: Temperature Profiles Landpack Landbox Hemp 70
Figure 42: Temperature Profiles Wolcool Fleece Liner 70
Figure 43: Temperature Profiles Supaso Ecoliner 71
Figure 44: Internal Temperature Profiles Insulating Materials 71
Figure 45: Package Temperature Profiles 72
Table 1: Share of Most Important Types of Plastics in Production and Waste 23

Table 2: Properties of Packaging Materials 36
Table 3: Properties to Calculate Average System R-Value of Insulated
Container Systems 45
Table 4: Melting Point PCMs in Insulated Containers - Comparison 51
Table 5: Latent Heat Experiment Results - Average 53
Table 6: Information Latent Heat Experiment 53
Table 7: Temperature Ranges 24 hour Monitoring with PCMs 60
Table 8: Temperature Ranges 24 hour Monitoring without PCMs 67
Table 9: WVTR for Supaso Ecoliner Samples at 12°C / RH 90% 68
Table 10: WVTR for Supaso Ecoliner Samples at 12°C / RH 90% 68
Table 11: Package Information from Österreichische Post AG 69
Table 12: Temperature Ranges Experienced Throughout Delivery 73
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1.0. Introduction
Cold chain logistics is the unbroken temperature-controlled supply chain of sensitive

goods from the point of production, storage, transportation and delivery to the final consumer.
The controlled movement of temperature sensitive, high value goods such as food and
pharmaceutical products plays an important role within global trade.
These goods are required by law to be transported between predefined temperature
levels, which must not fall below or reach above during any stage of the supply chain. The
majority of products subject to these conditions are shipped between 2°C and 8°C.
Unfortunately, thermal abuse is a high priority concern throughout the distribution process.
To ensure the effective transportation of these temperature-sensitive products
consumes large amounts of resources which contribute to the release of GHG emissions.
The perishable nature of such goods will require effective cold chain to maintain the
freshness and usability of the product (Babagolzadeh et al., 2020). The delivery of food and
pharmaceutical goods requires a temperature below 8°C under ambient temperatures of up
to 30°C, or less than 5°C in ambient temperatures of up to 25°C during shipment (Singh et al.,
2012).
Temperature sensitive goods face additional challenges as their transportation
requires more energy and resources to maintain constant temperature to guarantee the
quality of the product (Vamza et al., 2021). Delivering temperature sensitive goods to the end
consumer, requires a continual and uninterrupted cold chain. This requires the contents of
the package to maintain a specific temperature range to avoid spoilage. Cold chain logistics
typically require excessive amounts of packaging to ensure the product temperature is
maintained through the entire logistics process (Singh et al., 2012).
The delivery of temperature sensitive commodities from producer to consumer relies
on the efficient use of packaging in cold chain logistic solutions. Packaging plays a key role
in preventing the spoilage of highly perishable foods and biogenic materials, extends shelf
life and minimise spoilage (Emblem, A. 2012). Exposure to temperatures outside of those
stipulated can accelerate product deterioration to the point of spoilage, waste (due to
consumer preferences), loss of nutritional value and in serious cases, leading to events
which can cause products to become detrimental to human life if consumed.
Packaging is crucial to addressing the challenge of safety and efficiently delivering
temperature sensitive products. Innovative packaging aims to address waste and loss
reduction by preserving quality, as well as addressing safety issues by preventing food-borne
diseases and food chemical contamination (Guilard et al., 2018).
Therefore, insulated packaging can help maintain products within their stipulated
temperature ranges by providing an effective barrier to heat entering the package and
affecting the product. There are many conventional and novel materials on the market which
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can be used to help slow down the rate of heat transfer into a package throughout the
distribution environment.
As online shopping and global commerce become much more interconnected with
our daily lives, one-way packaging systems have emerged as a popular means of distribution
due to their resistance to heat transfer, insulating properties, consumer appeal and ease of
integration into the existing postal service infrastructure.
EPS is a conventional available material widely accepted for use in food and
pharmaceutical deliveries due in large part to the characteristics previously mentioned and its
compliance with food contact and safety requirements.
Yet, despite its mass adoption as an insulating material, a number of issues are
becoming of increasing concern, especially the issue of single-use plastics and that EPS is a
petroleum-based product which is not readily recyclable, biodegradable and that it typically
ends in landfill or the environment, which raises other sustainability problems.
As consumers are becoming increasingly aware and concerned for issues
surrounding end-of-life (EOL), waste management, resource consumption, global warming
and fossil fuel use, there is a drive to develop suitable alternatives which fulfil the functions of
thermal packaging in a manner which is sustainable, or at least has a reduced impact on the
environment. In an effort to reduce the environmental pressures of traditional cold chain
solutions, waste management issues and improve the quality and safety of food packaging
(Cavender & Zaho, 2014), there exist interest to developing thermal packaging solutions from
sources of novel and innovative materials.
In order to develop an effective, high-performing alternative to EPS packaging,
it is necessary to identify materials which are sustainable or circular in nature, are of bio
origin, can be readily disposed of with minimal effort to the consumer and the environment
and can provide the necessary levels of thermal insulation appropriate to their intended
application.
Therefore it is the goal of this master thesis to investigate the performance of a
number of novel thermal packaging solutions currently available on the market which are
aiming to provide suitable alternatives while effectively trying to decouple virgin material
consumption from economic development. Using identical cardboard boxes to allow for
uniform directional heat transfer to their contents, the aim is to measure how well each
insulating material performs in regards to keeping contents cold under particular
circumstances and analyse these various characteristics to measure the efficiency of novel
packaging solutions derived from hemp, wool and recycled paper to that of EPS insulation.
While been able to fulfill the basic functions of cold chain packaging which is to
contain, protect and preserve the contents of the package, innovative material solutions have
some disadvantages in comparison to the standard packaging due to their low mechanical
properties, sensitivity to humidity and novel market application (Aung et al., 2018).
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In order to meet the same functional requirements as traditional cold chain packaging,
it must be reasonable to subject these novel packaging solutions to the same testing
methods to determine in which applications the packaging material will be appropriate for use.
Therefore the topic of this thesis is to test the effectiveness of novel cold chain logistic
packaging materials to a standard EPS package to determine effectiveness of these
materials and determine the specific applications in which they may be applicable for use.
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2.0. Aim and Research Question
Packaging materials, particularly food packaging, is becoming an interesting yet

complex topic due to the social, environmental and economic impacts of its production, use
and EOL management. Environmental and social issues are leading to an increase in
legislation (particularly in Western Nations) which is aimed at curbing some of these
damages, implications on resource use and contribution to ever increasing greenhouse gas
(GHG) emissions. However, the correct type of packaging must be chosen to fulfill its
intended application with the right amount of packaging used to prevent over packaging,
which consumes more packaging material than is necessary. Equally important is the need
to avoid under packaging which could potentially risk the safety and quality of the packaged
goods. This is of particular concern to food and pharmaceutical products, as their waste
contributes to billions of dollars of lost product, environmental damage and large amounts of
resource consumption.
Further to that concern is the fact that perishable products require strict temperature
control throughout the supply chain to ensure they are delivered to the final customer in a
manner that is acceptable for consumption. While conventional insulating materials currently
on the market are mainly derived from non-renewable resources, there exists an opportunity
to replace them with those which are having a lower environmental and social impact.
In order to determine which novel packaging materials can provide a suitable
alternative to those in existence, laboratory tests will be undertaken to compare the
effectiveness of a range of thermally insulated packaging materials. A study and comparison
of various packaging materials will be undertaken to better understand the following:
 Different types of materials;

 Resistance to heat transfer;
 Characteristics of a good thermally insulated material;
 Susceptibility to moisture;
 Ease of fabrication and transport; and
 Effectiveness of phase change materials.
Although low cost, customer appeal, mechanical strength, application, environmental

and social concerns and waste management criteria are also acceptable factors which play
into selecting the final packaging product, the above criteria will test a range of alternative
materials against a widespread and commonly used product to better understand their
commercial application.
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3.0. Literature Review
3.1. Part 1 - A Brief History of Temperature Controlled Packaging
Cold chain logistics is a term given to the continuous and uninterrupted movement of
a temperature-controlled supply chain that includes the production, storage and distribution
of goods in order to maintain quality, safety and prolong deterioration from the point of
production to consumption (Lutzmayer, 2023).
This unbroken series of refrigeration has now become a necessity for transporting
fresh foods, meat, dairy, medicines and other products which require low-temperature ranges
in a safe and effective manner across the globe. Until several hundred years ago, goods
were transported wrapped in leaves and ice was gathered from mountains in winter which
were stored and became the genesis for the cold chain logistics we know today (Temp Aid,
2022). Noticeable moments in the history of cold chain transportation are listed below:
 1000s - Food wrapped in plant leaves and ice houses. Stored ice blocks gathered
during winter or shipped in from mountain towns.
 1800s - Ice continues to be the major method for cooling.
 1817 - The 1st commercial cardboard box made in England.
 1839 - Eduard Simon distills a resin from storax & accidentally creates the precursor
to Styrofoam).
 1848 - Alexander Twining experiments with vapor- compression refrigeration for
mechanical cooling.
 1851 - The first refrigerated boxcar entered service.
 1892 - James Dewar invents the vacuum flask due to research in cryogenics
 1895 - Carol von Linde designs scale production of domestic cooling units.
 1919 - Parke, Davis & Co. instructed to keep smallpox vaccine refrigerated.
 1939 - Fred Jones invents refrigerated trucking. Uses a roof mounted unit to
revolutionize the frozen food industry.
 1944 -Styrofoam is patented.
 1950s - Temperature controlled movement of pharmaceuticals and medical supplies
begin.
 1971 - The last ice-cooled reefers were retired.
 1985 - First temperature-controlled railcar "icebox on wheels."
 2021 - First biodegradable EPS shipping container announced.
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Biodegradable materials and packaging based on agricultural food waste residues
are providing an innovative, resilient and useful waste based economy for thermal packaging
(Guilard et al., 2018). The adoption of such packaging solutions can rapidly bring about the
decoupling of food packaging from fossil based feedstocks and allow nutrients to return to
the soil through circular economy forces (Guilard et al., 2018).
Thermal Packaging alternatives made from renewable raw materials which are also
biodegradable maybe a viable alternative to those manufactured from polymer based foams
(Singh et al., 2012). Manufactured from renewable and compostable materials, such
packaging solutions can also offer additional environmental benefits especially when they
can be composted in municipal or home-based composting systems (Wang et al., 2010).
Phasing out of plastic based packaging systems for recyclable and biodegradable
ones can also effectively divert much waste from landfills. Despite their reduced
environmental impact, these alternatives must demonstrate that they are suitable in regards
to their technical performance if they are expected to receive mass market adoption (Wang
et al., 2010).
Packaging solutions derived from renewable materials which are inherently
biodegradable or those using waste as a secondary raw material input are based on
principles of the circular economy (Escursell et al., 2021). Paper-based packaging solutions
are also considered to comply with circular economy principles if they are derived from waste
based sources or if treated in a manner which allows for their use as a secondary input
material. Paper-based packaging also provides products with protection against mechanical
forces (Gaikwad et al., 2016). Advantages of such materials include low production cost,
wide market share across various Industries, lightweight and the ability to be recycled or
biodegraded (Gaikwad et al., 2016).
As the number of products providing viable solutions to traditional cold chain
packaging increases, the choice of input material can make a difference between
competitors and contribute to distinctiveness within the market (Lecce & Ferrara, 2016).
Ultimately, materials should be easily understood by consumers with ease of communication
which can clarify the Innovative value of the packaging. This can help the competitiveness of
the packaging solution and make it more difficult for companies to introduce a similar product
on the market.
Due to the increase in global commerce and the proliferation of online shopping, the
consumption of fresh foods, vaccines, medical products and other temperatures sensitive
goods has increased. To keep up with quality and safety requirements, cold chain
transportation has become more important than ever (Vamza et al., 2021). Unfortunately, the
fluctuations in temperatures experienced by these goods in transport from point of production
to consumption can cause them to perish or become unsafe for human consumption.
However, these temperature fluctuations can be reduced with the aid of dry ice or cold packs
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and thermal insulation packaging (Vamza et al., 2021). Products which require constant
temperature regulation are particularly challenging because temperature monitoring is
required in order to guarantee the quality or freshness of the product, but also consume a
larger amount of resources than those which can be delivered without stringent temperature
requirements (Vamza et al., 2021). This makes the thermal Packaging industry energy
intensive and based on the ongoing consumption of fossil fuels (Zihare et al.,
2018). Therefore, the potential exists for the research and development of thermal packaging
Solutions that are recyclable, reusable, by degradable or manufactured from bio organic
material, and which can also reduce the need for consumption of resources needed to keep
product temperatures cold and stable.
Active cold chain is a method employed to preserve the quality of transported
goods which requires containers to be refrigerated and temperatures maintained throughout
the delivery of such goods. This method of shipping incurs a high cost to payload ratio and
forces location limitations to those which are easily accessible (Kucharek et al., 2020).
Passive cold chain systems involve the use of insulated shipping containers which
are then packed with insulated packaging materials and/or phase change materials (PCMs)
which are able to sustain low temperatures whilst in transport (Kucharek et al., 2020). The
use of passive cold chain systems increases the opportunity to deliver perishable goods
direct to the end consumer as the means of delivery can be undertaken by the existing postal
service and is often much cheaper than that of active cold chain solutions (Kucharek et al.,
2020).
Although the range of temperature sensitive goods delivered between -80°C through
to + 40°C, the most common delivery is of products within the range of 2°C to 8°C which is
suitable for a wide range of fresh foods, meats, dairy products and vaccines (Formato, 2020).
The correct insulated packaging solution can help maintain a temperature
environment within the acceptable product range which will aid in slowing down the
deterioration of the product until the point of consumption (Singh et al. 2008).
The delivery and distribution of temperature sensitive goods is typically undertaken by
one of three modes of thermal transportation systems; they are either carrier-controlled
thermal chain, one way systems or two-way systems. The choice of distribution method is
chosen by finding the right balance of payload, transit time, temperature sensitivity of the
product, consumer acceptance and cost (Singh et al. 2008).
Carrier controlled systems provide a thermal chain inside refrigerated containers
which are used to transport goods over a long distance while attempting to keep the
delivered goods between the acceptable temperature range. Two-way systems rely on
reusable shipping containers and packaging. One Way systems on the other hand have
emerged as the most popular temperature sensitive delivery method doing large part to their
ease of application, rapid packaging design and their ease of incorporation with PCMs and
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insulated cargo containers (Singh et al. 2008). They can also be easily handled throughout
the network of existing shipping service providers (Singh et al., 2012 ).
With an increasing awareness to the environmental impacts of packaging and
temperature controlled logistics, there have been many steps taken to increase the
sustainability of the sensitive supply chain. the transportation of such Goods consumes large
amounts of energy contributing to GHG emissions and other environmental issues
(Babagolzadeh et al., 2020). Additionally, the most important part of the supply chain is the
thermal packaging and this too is transitioning towards more environmentally friendly
material inputs, due in large part to raw material scarcity and increasing environmental
regulations.
3.2. Part 2 - Logistics of Temperature Sensitive Products
3.2.1. Importance of Packaging in Cold Chain Logistics
The function of packaging is to protect its contents from external influences and
damage, contain the contents and provide consumers or retailers with information specific to
the contents. Ultimately, this is to be achieved in a cost effective manner which satisfies
many industry and legal requirements and desires of the final consumer which include
maintaining safety of the contents and minimising the environmental impact of material loss
(Marsh & Bugusu, 2007). Figure 1 depicts the optimum packaging design as finding the
perfect balance of minimal material consumption and lowest possible environmental impact.
It should be noted that the optimum amount of packaging material will ensure that the
contents are delivered to the end consumer in perfect working order, free of damage. In
cases where contents are under packaged, the savings of packaging material may in fact be
lost due to damaged contents, which also require resources to create.
Figure 1: Optimal Packaging (Source: Pereira et al., 2015).

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Regarding cold chain logistics, protecting the contents does not only apply to
protection from mechanical stresses which may be experienced during the transportation of
the items, it also requires an element of heat resistance which, if exposed to, may render the
contents unusable. This is an especially important characteristic in the case of temperature
sensitive products. Regarding cold chain transportation, this is typically achieved through an
unbroken cold logistics chain, whether through shipment in a dedicated refrigerator and/or in
a temperature resistance box with or without the addition of PCMs.
With the rise of online commerce, home food delivery (of both fresh and prepared
foods) and the increase in global commerce and distribution of pharmaceutical products, it is
critically important to ensure goods are delivered in a condition that ensures safe
consumption in a timely manner by the end consumer.
Packaging and technologies offering improvements to the efficiency, sustainability
and economics of global food and pharmaceutical supply chain will only be adopted by
actors if the food or product waste reduction measures are profitable to do so, or if they are
at least cost effective when adopting and implementing throughout the system (FAO, 2015).
3.2.2. Food Products
Although temperature sensitive products can be delivered anywhere from -10°C to

80°C, the most common temperature range for products is between 2°C and 8°C and is
relatively important as this is the range at which most goods for consumption are delivered.
Pharmaceuticals, vaccines and medicines require an environment within this temperature
range to ensure safe consumption at the point of delivery.
Frozen foods, meat and fresh produce are kept cold in order to retain nutritional value
and visual appearance (Singh et al. 2008). Cooler temperatures are the most effective way to
slow the ripening process which leads to deterioration, although this is not true for all
products such as milk, dairy and cheese whilst other tropical products can succumb to
‘freezer burn’ if temperatures reach too low (Singh et al. 2008).
Fish require an ideal storage temperature close to 0°C until the point of consumption.
Freshly cut flowers and Horticultural products are best kept between 0°C and 12°C in order
to satisfy freshness and acceptable visual properties (Singh et al. 2008).
Heat is hazardous to many products during transportation and storage because it
provides an environment for bacterial growth which may result in shorter shelf life or spoilage
of the product completely.
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3.2.3. Food Waste
Food waste is defined as ‘the decrease in quantity or quality of food and agricultural
and fisheries products intended for human consumption (FAO, 2015). This results from the
reduction in quality of and nutritional value of the food products leading to food safety issues.
Food waste on the other hand refers to the discarding of food that was fit for human
consumption (FAO, 2015). Across the globe, the figures related to food waste are estimated
to equate for 30% of cereals, up to 50% of fruits vegetables and root crops, 20% of oil seeds,
meat and dairy products and up to 35% of fish (FAO, 2015).
Unfortunately and especially in mid to high income countries, the cause of this waste
can be attributed to policies and regulations, economic forces and consumer preferences
when it comes to the selection and consumption of food. Further still, quality and safety
standards have been applied in ways which can unintentionally lead to the early disposal of
food which can still be safely consumed by humans.
The removal of otherwise consumable food from the supply chain incurs tremendous
amounts of loss not only in terms of economic value, but also land, water and energy use
and other resource inputs which ultimately go to waste. The economic value of global food
waste due to this problems is estimated to be around $1 trillion annually (FAO,
2015). Improper handling of food products within the cold chain are also contributing factors
which result in these economic losses and reduction of food availability (Wu & Hsiao, 2021).
Research suggests that up to 35% of foods requiring unbroken cold chain logistics
are exposed to temperatures which ultimately cause damage or create health risks for food,
contributing to the loss of products from the value chain (Wu & Hsiao, 2021).
3.2.4. Food Safety Issues
Food exposed to unacceptable temperature ranges during dispatch and logistics

operations can cause microbial growth which has serious side effects such as the reduction
in the quality of products, spoilage and increased risk of food poisoning and other health and
environmental issues (Wu & Hsiao, 2021).
With an estimated global market for low temperature foods to be valued at around
$300 billion in 2023, the continual development of cold chain logistics is vital to ensuring food
can be maintained at low temperatures throughout the logistics chain to help maintain
quality and reduce food safety issues (Wu & Hsiao, 2021).
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3.2.5. Non - Food Products
Food is not the only product category which requires an unbroken cold chain
throughout its transportation from manufacturer to end consumer. The global market for
pharmaceutical logistics is expected to grow from $84.5 billion in 2022 to an estimated
$163.9 billion in 2030 (Grand View Research, 2023). Therefore, the reliance on cold chain
transportation and packaging will continue to grow in size and scope as the production and
distribution of pharmaceutical and medical products rely on an uncompromising transfer of
goods. In 2005, 40% of drugs distributed required cold chain transportation due to their
sensitivity to temperature fluctuations (Singh et al., 2012).
As the entire pharmaceutical industry is beginning to shift away from products derived
from chemical constituents towards that of biologics and bio-similar origin, research suggests
that most of the pharmaceutical market will be made up of these products in the coming
decade (Pelican BioThermal, 2019).
When the European Union (EU) updated the good distribution practices (GDP)
standards in 2013, there was a requirement that all pharmaceuticals - not just those within
the 2°C to 8°C range - to be transported within the temperature range specified on the
products label. This resulted in room temperature controlled products (which make up 90% of
pharmaceuticals that are not refrigerated) to also be transported under temperature
controlled conditions (Basta, 2018).
This driving factor has experts in the pharmaceutical and medical supply chain
suggesting that the shipment of products can be broken down into 51% for the ambient
temperature range, 31% requiring refrigeration, 17% requiring a continual frozen cold chain
and the remaining 32% of products not been allowed to freeze (Sykes, 2018).
However, as the nature of pharmaceutical products begin to change, there will be an
increase in the demand for products to be transported in an unbroken refrigeration range of
2°C to 8°C.
Monoclonal antibodies, anti-diabetics, insulin's, dermatology and hormone products
make up 83% of major global market cold chain medicine sales, with the 20 largest
pharmaceutical companies accounting for 86% of cold chain product sales in 2021.
Additionally, vaccines having been identified as the next high volume cold chain market
within the pharmaceutical industry (Pelican BioThermal, 2019).
3.2.6. Non - Food Waste
As the demand for healthcare products increases, so too does its waste production
and energy and resource consumption. Currently the healthcare industry is responsible for
an annual production of 4.2% of global GHG emissions (Pichler et al., 2019).
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Medicines and pharmaceutical products relying on cold chain logistic systems from
their point of manufacture until they reach their patient, consume far more energy than those
suitable for ambient temperature transportation. It has been suggested by the WHO that up
to 50% of global vaccines are wasted due to temperature damage, while others suggest the
bio-pharmaceutical industry suffers losses to the figure of $35 billion annually due to the
failure of broken cold chain logistics (Lutzmayer, 2023), (Pelican BioThermal, 2019).
3.2.7. Non - Food Safety Issues
Increasing regulatory requirements across the globe are exerting pressure on supply
chain actors to ensure attention is paid to temperature sensitive pharmaceutical products. As
the volume and value of these products increases, ‘ship-to-label’ requirements and proof that
products have been transported within their approved temperature range are factors driving
quality standards and demand (Pelican BioThermal, 2019).
Avoiding temperature damage functions well during both the first and longest leg of
pharmaceutical transportation. It is typical that issues occur more frequently during the ‘last
mile’ and last stage of the supply chain this is in large part due to lapses in safety and
handling as cold chain medicines are transported to their final destination in environments
where temperature is not well controlled and fluctuations to temperature exposure may occur
(Lutzmayer, 2023). This all leads to a stricter regulation of these highly sensitive goods.
Consider these products can be developed from complex combinations of sensitive
amino acids, other acids and sugars, all of which require an unbroken cold chain in order to
avoid contamination and the formation of potentially harmful substances (Lutzmayer, 2023).
3.2.8. Phase Change Materials
Phase change materials can be considered as a thermal energy storage device which
are used to assist in maintaining a manufacturer's sensitive product within a particular
temperature range (Formato, 2020). It is essential to keep such products within the specified
temperature range throughout all phases of the logistics chain. It is typical that PCMs help to
maintain temperature sensitive products such as fresh produce, dairy, medicines and
pharmaceuticals and flowers to be delivered through an unbroken temperature chain in the
range between 2°C to 8°C.This helps increase the length of time products are shipped within
a different temperature range. PCMs are chosen so that the phase change temperature falls
within the required temperature range of the product been shipped (Formato, 2020).
As the PCM changes it's phase from solid to liquid (typically around 5°C) It
essentially prolongs the time of temperature control of the product via the effect of latent heat
19
transfer (Formato, 2020). The use of PCMs will aid the thermal performance of the
packaging material while also contributing to package weight (Wang et al., 2020).
3.3. Part 3 - Conventional Cold Chain Packaging Material
3.3.1. Expanded Polystyrene Inlays
The most popular thermal packaging material currently on the market is EPS due in
part to its relatively low cost to produce, low thermal conductivity and low density (typically
between 13.5 kg/m3 and 28 kg/m3) making it a light weight, yet functional material for
packaging and transporting temperature sensitive goods (Chen et al., 2015, Vamza et al.,
2021).
Typically synthesized from ethylene and benzene, chemicals which are derived from
the process of petroleum refinery, this classifies polystyrene (PS) as a non-renewable
polymer (Vamza et al., 2021). Unfortunately when exposed to ultra violet (UV) radiation and
outdoor weather conditions, experiments have shown that EPS can lose up to as much as
5% of its mass after one month to ongoing exposure (Vamza et al., 2021). The
consequences of improper disposal can result in the release of micro and nano-particles into
the environment. Despite a thermal conductivity of 0.046 W/m°C, the carbon footprint
associated with EPS production is considerable, equating to 64.98 kg of CO2 eq./m3 (Singh
et al. 2008, Vamza et al., 2021).
The use of EPS as an insulating material has changed in recent years. Previously
manufactured into ready to use boxes, pressures from the environment and political
landscapes have now seen the use of EPS reduced to the use of inlays. This not only has
the advantage of significantly reducing demand for non-renewable materials but also
reducing packaging volumes. This is reduced by been able to insert cut-to-size EPS Inlays
into cardboard boxes which also reduces overall volume and weight of the package been
delivered.
3.3.2. Environmental Considerations of Conventional Packaging Material
EPS is a widely used material in the packaging sector, particularly due to its high
impact strength, acoustic isolation, light weight, ease of processing and heat insulating
properties. The packaging sector is estimated to consume 47.9% of all global EPS (Marten
& Hicks, 2018). Unfortunately, many products made from EPS are characterised by a short
useful service life. (Samper et al., 2010)
In Europe in 2015, 49 million tons of oil and gas were needed for the production of
plastics with about 40% used for packaging as shown in Figure 2 (Kaiser et al., 2017).
20
Figure 2: Fields of Application of Plastic Materials and Polymer Types Predominately used in
Packaging (Source: Kaiser et al., 2017).
A significant portion of plastic consumption has come as a result of packaging use,

and is responsible for a significant amount of waste produced across the EU as described in
Figure 3.
Figure 3: Distribution of Plastic Applications in Consumption and Waste in the European Union
(Source: Worrell & Reuter, 2014).
Despite the many beneficial characteristics of EPS, its main problem can be
contributed to its low density (in the range of 10–25 kg/m³) which increases the cost to
transport this waste material to recovery plants (Samper et al., 2010). As EPS is not a readily
recyclable material, much of its waste will end in landfill or incineration, leading to severe
environmental impacts (Lim et al., 2021). Additionally, EPS is considered too brittle for many
21
recycling systems to handle and to add to its lightweight properties, this makes transporting it
long distances for treatment cost prohibitive (Marten & Hicks, 2018).
Polystyrene is very stable and extremely hard to degrade in the environment after
disposal (Ho et al., 2017). While this may be considered a positive for packaging systems,
once it enters the environment, through inadequate or irresponsible disposal, it typically ends
up in water ways where fragmentation by waster and wind can lead to widespread
transportation of significant quantities of the material (Turner, 2020).
Once in the environment, it is particularly difficult to retrieve and is ingested by a wide
variety of marine animals leading to gastro-intestinal blockage exposing animals to harmful
chemicals with these impacts eventually working their way up the food chain (Turner, 2020).
3.3.3 Advantages and Disadvantages of Conventional Packaging Material
While some of the novel cold chain packaging solutions provide a more efficient
thermal insulation over conventional counterparts, many fall short in other respects.
Therefore it is necessary to gather and assess the most important criteria from the
perspective of those involved in cold chain transportation.
Currently, polymeric foams are the choice material due in large part the wide
application of foaming technologies used in product thermal packing (Wang et al., 2010).
This is achieved by the low cost, lightweight and low thermal conductivity making them
ideally suited for use with products that require shipping at chilled temperatures (Wang et al.,
2010). As such, these products dominate the market with the total market share of over 60%
in the UK alone (Wang et al., 2020). However, the contribution of packaging to the
accumulation of municipal solid waste (MSW) sites has garnered global attention during
large part to the technical difficulties in economically collecting separating and cleaning
commingled and highly contaminated post-consumer (PC) waste for recycling purposes
(Wang et al., 2010). This has resulted in the development of policy and frameworks
specifically aimed at the reduction of packaging waste especially in the EU (Molina-Besch &
Pålsson, 2016). Yet, despite the low cost and the high performance ratio of polymeric
materials, Government regulations on this type of packaging material has placed limits its
use as well as manufacturing (Wang et al., 2020).
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3.4. Part 4 - Novel Cold Chain Packaging Materials
3.4.1. Novel Packaging Materials
Consumers are becoming increasingly aware of the environmental and social

impacts of packaging throughout the supply chain (Beitzen-Heineke et al., 2017). Shifting
sentiment towards plastic as a packaging material is providing opportunities for novel
packaging alternatives to replace conventional solutions currently available on the market. In
the cold chain market, insulated packages used to deliver temperature sensitive products are
typically made from polyethylene (PE) or EPS (Wang et al., 2020). Polystyrene in particular
accounts for up to 10% of plastics production and is responsible for 13 - 17% of the total
share in plastic waste volume as highlighted in Table 1 (Megale Coelho et al., 2020).
Table 1: Share of Most Important Types of Plastics in Production and Waste (Source: Megale
Coelho et al., 2020).
However, as the demand for long-haul transportation of fresh goods food and
medicines increase with the rate of global commerce, conventional packaging materials no
longer satisfy the requirements of temperature controlled delivery, MSW regulations and
environmental considerations.
Packaging solutions which can address issues of food waste and lost prevention
must ensure they preserve food quality while adhering to highly regulated standards (Guilard
et al., 2018). Maintaining food safety, preventing food borne diseases and eliminating
contamination are crucial issues which must be addressed while providing a viable
alternative capable of preventing plastic waste contamination and conserving critically
important resources. Due to these concerns, there have been an influx of novel cold chain
packaging solutions entering the market as alternatives to conventionally used materials.
Packaging derived from natural materials such as wooden cellulose, biodegradable polymers
23
from agricultural food waste, mycelium and feathers are just a few of the currently explored
options (Wang et al., 2020, Guilard et al., 2018). While some of the more environmentally
friendly cold chain packaging solutions can provide adequate thermal insulation compared to
conventional packaging solutions, many fall short in some respects relating to industry
specific criteria which are essential for dealing with temperature sensitive product
transportation (Vamza et al., 2021).
Despite being environmentally friendly in nature, several downsides exist for such
materials including high manufacturing costs, slower production times, variable thickness and
susceptibility to water through capillary forces (Wang et al., 2020, Vamza et al., 2021).
3.4.2. Environmental Considerations of Novel Packaging Materials
The concept of sustainability is not a recent phenomenon. Emerging in the late 1980s
after the term was coined in the 1987 report Our Common Future: Report of the World
Commission on Environment and Development, and was described as 'development that
meets the needs of the present without compromising the ability of future generations to
meet their own needs' (Bruntland, 1987). Since then, global efforts have been made to be
mindful of the amount of fossil resources available for manufacturing, while limiting the
release of GHG emissions into the atmosphere (Escursell et al., 2021).
Packaging materials have many benefits including maintaining the manufacturing
processes of food and other products and enable these products to be shipped long
distances from their point of production to the point of consumption (Marsh & Bugusu,
2007). However, the point that packaging has a direct impact on material consumption and
energy use and logistics and waste production, consideration is paid to weight and volume
as this directly influences energy required for transportation and cold chain use (Escursell et
al., 2021). Therefore, packaging solutions must balance the critical importance of food and
product protection against sustainability issues such as energy and material use, resource
consumption, social and environmental concerns, health and safety requirements and
regulations surrounding contaminants and methods of packaging disposal (Marsh & Bugusu,
2007).
To achieve source reduction, waste prevention is achieved by reducing the total
amount of and toxicity of packaging materials (Marsh & Bugusu, 2007). This can be achieved
by changing the design manufacturing process, purchasing decisions, or use of particular
materials. Specifically, source reduction will include the light-weighting of packaging
materials, the choice of non-toxic input material and other factors which lead to
environmental benefits such as the likes of resource conservation environmental protection
and the overall reduction of GHG emissions. Figure 4 describes how a wide range of
24
opportunities which can be enacted to help make for a more efficient use of material and
reduce the overall amount of resources entering the waste stream.
Figure 4: Opportunities for Material Efficiency (Source: Megale Coelho et al., 2020).
To achieve such goals, the EU has revised legislation in 2015 under the ‘Circular
Economy Package’ with new proposals that each member state was to adopt by 2030.
Notably this included targets to achieve 65% of all MSW and 75% of packaging material to
be recycled (Escursell et al., 2021). In order to reach the goal of 75% packaging waste
reduction ‘packaging shall be designed, produced and commercialized in such a way as to
permit its reuse or recovery, including recycling, and to minimize its impact on the
environment when packaging waste or residues from packaging waste management
operations are disposed of (Molina-Besch & Pålsson, 2016). This has ultimately led to the
development and investment into novel packaging solutions for the cold chain Packaging
industry with the aim of reaching recycling and recovery targets which all EU member
states must adhere to.
Novel insulation packaging solutions were chosen on the grounds of their
environmental performance. Principles of the circular economy dictate that packaging
materials shall maintain closed material loops and if not possible these cycles should try to
retain material quality to the point where the packaging can serve its intended function, while
retaining the highest economic value possible (Megale Coelho et al., 2020). This is
demonstrated by the circular economy systems diagram (also know as the butterfly diagram)
in Figure 5. The ultimate outcome is to decouple material use from economic development
and the challenge for novel thermal packaging materials is that they must achieve health and
safety as well as mechanical and thermal performance qualities whilst reducing the need for
virgin material input (Megale Coelho et al., 2020).
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Figure 5: Circular Economy Systems Diagram (Source: Ellen MacArthur Foundation, 2019).
Circularity of the chosen packaging solutions is achieved by the selection of recycled

raw materials which ultimately reduce GHG emissions in production, transportation and
consumption. The life cycle of the novel packaging solutions is circular in nature which
helps aid the sustainability process. While in the past, the main focus has been on
reducing the amount of packaging material per unit of packaged volume which would offer
only marginal levels of improvement (Megale Coelho et al., 2020). In the case of novel
packaging solutions constructed from sources of waste material, the change to material
reuse, recycling or biodegradation can be considered positive as material value is retained
and environmental damage is kept to a minimum. Packaging materials were selected on
the basis that they were produced from sources of secondary material inputs and can be
broken down and ultimately returned to the earth. This aligns with the biological cycle of
the butterfly diagram in Figure 5 and fulfills the criteria for circular economy in the field of
thermal packaging solutions. However, to assess the ultimate impact of each novel
packaging solution, in depth life cycle assessment (LCA) information is required.
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3.4.3 Advantages and Disadvantages of Novel Packaging Materials
There are many advantages of using novel packaging materials, most notable that
they are capable of performing as good as, if not better than conventional materials.
However, the advantages go beyond performance characteristics. In order to reduce
environmental impact, many materials apply principles of the circular economy in that they
are sourced from raw or recycled materials, and aim to reduce, if not avoid the impact of
becoming residual waste. The fact that many materials are inherently renewable, from
natural sources and are safe for handling and disposal could be considered as a positive,
especially for businesses and organisations who wish to reduce the environmental impact of
their packaging choices. Been easily adaptable into the existing packaging and delivery
system is another advantage. However, with new materials, may come some disadvantages
to users and consumers. Due to the novelty, there may not be a large demand for new
products. This could lead to limited availability and supply chain issues when sourcing raw
materials for their production. Cost, performance and durability of new materials may also
come into question and restrict wide spread adoption. Due to materials been from natural or
recycled sources, another disadvantage could be in terms of standardization and quality
control of materials and claims of environmental benefits may be lost through other parts of
the supply chain.
It may also be considered that although claims of materials been collected in the bio
waste stream, this will be particular to certain areas. In the case of Woolcool and Landbox, it
is claimed that if the waste cannot be disposed of in the bio waste stream, then materials can
simply be composted or used around the house (Woolcool, 2023, Landpack, 2023a). This
may be difficult to do in the case of people living in apartment complexes or if hundreds or
thousands of packages are received annually. The likely scenario will be that materials will
be discarded in the conventional waste stream and will also end in landfill. Source separation
is another area of concern. Unless effort is taken to separate films from the internal materials,
then it is likely that insulating materials will end in landfill or materials will be mixed which will
not allow for them to be recycled.
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4.0 Materials
4.1 EPS Inlays
EPS is one of the most popular materials used in the cold chain transportation of
foods, medicines and other sensitive products. In the past, boxes were prefabricated and
shipped to packaging plants,however, the need to reduce overall volume and material use
has seen the use of inlays become popular in modern times. These inlays can be extremely
modular as they can be cut to size and and suitable for use with existing cardboard shipping
boxes which are effective in reducing weight and volume.
Figure 6: EPS Inlays Inside Postal Box.
EPS is derived from the polymerization of phenylethane (styrene monomer), and is

produced in white beads with a number of closed cells, solidly supported and heat-sealed
tangentially to one another allowing air to be trapped inside. The foam is manufactured by
treating crystalline PS with a blowing agent to create a cellular structure in the material
(Castro et al., 2017).
The addition of air in the structure adds to its low density (in the 10–25 kg/m³ range),
which increases the volume and cost of transportation (Samper et al., 2010). Thermal
conductivity is anywhere between 0.036 and 0.046 W/mk depending on the density (Yücel et
al., 2003). This makes it excellent for a wide range of use cases mainly due to its high impact
strength, acoustic isolation, lightness, and ease processing (Samper et al., 2010).
Unfortunately EPS causes a plethora of problems in all stages of its lifecycle, as the
production of polystyrene is an energy intensive process, and associated environmental
impacts (Marten & Hicks, 2018). EPS packaging has a carbon footprint of a typical styrofoam
box will range from 3.5 - 6.7 kg CO2eq./kg depending on the method of disposal (Supaso,
2023). It is not uncommon for EPS products to have a short service life as it is brittle and
28
susceptible to breaking, and as a petroleum product with no clear wide spread recycling
pathway typically ends its life in landfill or incineration (Marten & Hicks, 2018, Samper et al.,
2010, Lim et al., 2021).
Figure 7: EPS Inlay.
Information regarding the inlays used in the following experiments are as follows:
Dimensions:
Top and bottom inlays: 315 x 285mm
Side inlays (Long): 285 x 210mm
Side inlays (Short): 270 x 210mm
Average thickness: 20.1mm
Total inlay weight: 177.25g
Density of EPS: 0.01 - 0.025 g/cm3 (Yücel et al., 2003)
Thermal conductivity of EPS: 0.036 - 0.046 W/mK (Samper et al., 2010)
29
4.2. Supaso Ecoliner
Supaso GmbH is a sustainable packaging company based in Austria developing a

range of insulating materials for the food and pharmaceutical industry. They have a number
of products developed from recycled paper. The inner material is cellulose fiber sourced from
recycled waste paper and inserted into pillows made from a PE foil. This is all done through a
low-energy-intensive recycling process. The Supaso Ecoliner used in the following
experiments is a versatile product which can be assembled in seconds and easily integrated
into existing packaging solutions. The pouches are produced in different lengths and are
designed to keep contents cold for more than 48 hours (Supaso, 2022).
Figure 8: Supaso Ecoliner (Without Top Cushion) Inserted into Post Box.
Cellulose insulation is collected from recycled sources which help the packaging
material achieve a CO2 neutral balance. The low-energy-intensive production process helps
to further reduce the environmental impact of their products and as such have been certified
as “climate neutral.” Additionally, the emissions value of the product has been certified as
0.298 kg CO2eq/kg. Although the product is designed for multiple uses, the product can be
easily disposed in existing waste streams due to the product consisting of over 97% recycled
paper and the outer foil constructed from high density polyethylene (HDPE) film (Supaso,
2023).
30
Figure 9: Supaso Ecoliner.
Information regarding the Supaso Ecoliner are as follows:

Dimensions:
Long liner: 1,250 x 315mm
Top and bottom liner: 315 x 315mm
Average cellulose thickness: 40mm
Average foil thickness: 0.5mm
Total weight: 1,431.45g
Density of waste paper: 0.238 g/cm3 (Odusote, J., 2016)
Thermal conductivity of recycled cellulose fibers: 0.042 W/mK (Brzyski et al., 2019).
Figure 10: Internal Contents of Supaso Ecoliner.
31
4.3. Landpack Landbox Hemp
Landpack GmbH is a German based company hemp and straw as the basis for
creating a range of insulating packaging products. The inside material of the Landpack
Landbox Hemp is commercially available virgin hemp fibers sourced from France, the
Netherlands and Romania. In order to create their packaging, the hemp fibers are baled and
then wrapped in a Polylactic Acid (PLA) liner, which is supposedly compostable, however the
insulating material is sold as a single use product. The materials are easily assembled and
can be readily integrated into the existing packaging system. Despite been sold as a single
use product, it can be used with certain precautions and is compliant with food contact
regulations (Landpack, 2023).
Figure 11: Landpack Landbox Hemp (Without Top and Bottom Liner) Inserted into Post Box.
At its end of life, Landpack claims that because it is a natural material, it can be
placed into the organic waste collection, and in Germany this method of disposal is
apparently exempt from disposal fees. As a material, hemp is able to grow up to 4cm per day
and is a carbon sequestrating while also improving soil quality. Landbox is reported to emit
0.41kg CO2 eq. Throughout the supply chain, consumes 0.05L of water per kg and can save
up to 0.34kg CO2 eq through biogas extraction when deposited into the German bio waste
stream (Landpack, 2023a).
On matters of thermal performance, claims on the Landpack website the that
Landbox Hemp can maintain temperatures from 0°C - 8°C at outside temperatures of 30°C.
The material is also moisture regulating due to the fact that hemp fibers are able to absorb
up to 80% of their own mass (Landpack, 2023a).
32
Figure 12: Landpack Landbox Hemp Liner.
Information regarding Landpack Landbox Hemp are as follows:

Dimensions:
Liner: 1,000 x 320mm
Average fiber thickness: 20mm
Average PLA thickness: 0.2mm
Total weight: 574.2g
Density of hemp fibers: 0.86 g/cm3 to 1.6 g/cm3 (Na & Shubhashini, 2013 & Liu et al.,
2017)
Thermal conductivity of hemp fibers: 0.0146 - 0.0356 W/mK (Lekavicius et al.,
2015).
Figure 13: Internal Contents of Landpack Landbox Hemp Liner.
33
4.4. Woolcool Fleece Liner
Woolcool is the trading name of The Wool Packaging Company Limited which is
located in the United Kingdom. They specialize in wool based insulating products for the food
and pharmaceutical industry. The Woolcool Fleece Liner used in the experiments is
constructed from untreated wool sourced in the UK, cleaned and finally wrapped in a
perforated PE film which will prevent direct contact with any food products. Claims on the
Woolcool website suggest that Woolcool is capable of keeping products at temperature for
up to 72 hours (depending on food type, temperature range and ice usage). It is simple to
use and a perfect substitute to conventional insulating packaging solutions (Woolcool, 2023).
Figure 14: Woolcool Fleece Liner (Without Top and Bottom Liner) Inserted into Post Box.
Woolcool claims to be a sustainable packaging solution that uses renewable sheep’s

wool that are certified with ISO certificates (Woolcool, 2023).
Although the materials are durable, the package is designed for a single-use
applications which are dependant on the quality of the liner after use. At its EOL, Woolcool
can be disposed of in the organic waste system where it is biodegraded and the nutrients
returned to the earth. PE film can also be recycled within the existing recycling system in the
UK. The product is said to retain the natural smell of sheep’s wool (Woolcool, 2023).
34
Figure 15: Woolcool Fleece Liner.
Information regarding Woolcool Fleece Liner are as follows:

Dimensions:
Liner: 1,000 x 320mm
Average fiber thickness: 25mm
Average PE thickness: 0.65mm
Total weight: 455.81g
Density of Non-medullated wool: 1.307 g/cm3. (Merrick et al., 1998)
Thermal conductivity of wool fiber: between 0.038 - 0.054 W/mK (Dénes, et al.,
2022).
Figure 16: Internal Contents of Woolcool Fleece Liner.
35
4.5. Boxes
Boxes for use in the following experiments were purchased form Österreich Post AG.
This is to ensure consistency between packages for which the insulating materials will be
placed. The size Large paket box is made from cardboard flute and is a standard size box
used to send goods within the Austrian post infrastructure. Details are as follows:
Dimensions:
External: 380 x 305 x 250mm
Internal: 315 x 287 x 244 mm
Volume: 0.022m3
Average weight: 500.69g
Average thickness: 3.31mm
Density of corrugated cardboard - 0.69 g/cm3 (Density Procedure 1, 2016)
Thermal conductivity of corrugated cardboard - 0.05 - 0.12 W/mK (Cekon et al., 2017).
Figure 17: Österreich Post AG Paket Box Large.
Properties of packaging materials

Material Thermal Conductivity (W/mOC) Density (g/cm3)
Corrugated cardboard 0.05 - 0.12 0.69
EPS 0.036 - 0.046 0.01 - 0.025
Recycled paper 0.037 - 0.042 0.238
Hemp 0.0146 - 0.0356 0.86 - 1.6
Wool 0.038 - 0.054 1.307
Table 2: Properties of Packaging Materials.
36
4.6. Temperature Monitors
Tive Tags are passive temperature loggers available for end-to-end cold chain
monitoring of temperature-sensitive shipments.
The NFC-Enabled smartphone temperature sensors from Tive, Inc. (Boston, MA,
USA) were used to take temperature measurements inside and outside of the insulated
packages. Tive produces paper thin, flexible tags which are NFC enabled and are capable of
recording over 4,000 measurements over their 1 year life cycle.
The devices were factory calibrated and is capable of operating in temperature
ranges -30OC to +50OC. The temperature monitors are water resistant, have a thickness of
around 1mm and have a 1 year battery life.
Temperature accuracy is ±0.5°C, from -10°C to +50°C.
Figure 18: Tive Tag Temperature Logger (Front and Rear).
4.7. Cold Packs
Frozen packs from Supaso GmbH were used as the PCMs in the following
experiments. The pure water packs were chosen due to their ease of disposal, simply by
pouring the contents down the drain and ease of recycling the HDPE film. Details of the
frozen ice packs used are as follows:
Dimensions: 300 x 150 x 25mm
Average weight: 1,024.01g
37
Figure 19: Supaso Frozen Ice Pack.
4.8. Kraft Paper Gel Packs
Coolways is a Netherlands based company which specialises in developing chilled

packaging solutions. Having experience in the pharmaceutical, food, fish and agriculture
industries. Their kraft paper gel packs offer an environmentally friendlier alternative to
traditional plastic based packs while retaining the same performance characteristics.
Figure 20: Coolways Kraft Paper Gel pack.
The GP04000BKP 400g Gel Pack. Constructed from kraft paper and contains a
proprietary gel formulation which must be disposed of in the waste stream due to the nature
of the contained solution. These packets were used as the “dummy packages’ which were
meant to simulate a food product. They were chosen for their ability to hold a constant
temperature of any environment they have been sitting in and were used in pace of real food
item when undertaking the following experiments (Coolways, 2022). Details as follows:
Dimensions: 200 x 150 x 20mm
Average weight: 405.01g
38
5.0. Method
5.1. R - Value of Insulating Packaging Materials
Scope: The R-value is the ability of a material to resist heat flowing an

insulating layer. It is dependent upon the size and shape of the insulating
package,the material from which it is constructed as well as the thickness of
the insulating layers. The R-value is therefore a property of the package as a
system, not specifically the insulating material (Singh et al., 2008).
To determine the R-value, an ice-melt test is undertaken which is
based upon the of latent heat which is described as the energy required to
melt 1 g of ice at 0°C (Legates, 2005).
A known quantity of ice is placed inside each insulated package and
the heat transfer into the package is able to be calculated from the amount of
ice melted by the end of each time period.
Test undertaken in accordance with test method ASTM D 3103 -
Standard Test Method for Thermal Insulation Quality of Packages.
Materials: Insulated packages, scale, known quantity of ice (approx. 1.0kg), measuring
cup, non-metallic containers, freezer, thermometer, hydrometer, temperature
logger, packaging tape, storage area (ambient temperature).
Method: Precondition ice for use in test by pouring known quantity of water into
non-metallic container and placing in freezer for 24 hours. Remove ice from
freezer and allow to condition for 1 hour before beginning experiment. This will
ensure ice is at melting temperature of 0°C uniformly and not at the
temperature it was stored at in the freezer. Drain any water and record the
weight of the remaining ice. Place the remaining ice in a non-metallic
container in the centre of each insulating package. Temperature loggers are
placed as indicated by ASTM d 3103. Ensure insulating materials are placed
and container is sealed as per manufacturers instructions. Insulating
packages are stored in the test environment on a raised wooden platform in a
manner in which the package is not in contact with the floor or wall and each
package separated from each other by at least 152mm. Record external
temperature and humidity at intervals of 0, 6, 12, 18 and 24 hours. Internal
temperatures are recorded at 5 minute intervals. Additionally, every 6 hours,
remove excess water and record weight of remaining ice. This method is
repeated for each insulating package.
39
The aim of the experiment is to have some ice left in the bucket. A few cases were
noted where the entire quantity of ice was melted during the test. In such cases, the
melt rate could not be calculated. For the melt rate to be calculated, ensure there is
enough ice to maintain constant melt temperature of 0°C as it melts. A constant
temperature difference must be maintained throughout the test period.
Melt rate is then calculated as the weight of water collected in kg divided by the test
time in hours.The internal surface area of each system, ambient temperature of the
test room and melting point of ice are know, it is then possible to calculate the the R-
values for each system. Each system was tested twice and the average results
reported. A constant temperature difference was maintained for as long as
there is some amount of ice left inside the bucket because the ice maintains a
constant temperature of 0°C as it melts.
The system R-value for the package is calculated using the following
formula as defined in Singh et at., 2007:
(�� )(�� )

�� − �� =
(�� )(�� )
Where:
Surface area = inside surface area of the package (m2)
Temperature difference (°C) = ambient temperature − melting point of ice
(23°C − 0°C = 23°C)
Melt rate (kg/h) = weight of water collected divided by test time
Latent heat = 334kJ/kg (Legates, D.R., 2005).
Average R-value for 6, 12, 18 and 24 hours is expressed as m2°C/W.
The R-value is calculated as the whole system package as it includes

the size, shape, materials, thickness of the box and insulating materials and
their overall effectiveness at resisting heat flow. Therefore, the System R-
value is the property of the entire package, not just the insulating materials.
5.2. Melting Point of Phase Change Materials
Scope: PCMs are critical to keeping temperature of insulated packages

constant throughout the entirety of the packages journey. They are needed to
ensure contents arrive within acceptable temperature ranges. The time and
melting point of PCMs in each insulating container is to be determined.
40
Materials: PCMs, freezer, temperature logger, aluminium foil, insulating containers, timer.
Method: Place 2 PCMs in the freezer for 24 hours. Remove and place a data logger
between them and wrap in aluminium foil to reduce heat loss. The set up is place into
each of the insulating packages and sealed as per the manufacturers instructions.
Monitor and record temperature vs time curve. As the PCMs are made from
water, the melting temperature is observed as that which is above 0°C. Test
undertaken in accordance with test method ASTM D 3103 - Standard Test Method for
Thermal Insulation Quality of Packages.
5.3. Latent Heat and Heat Absorption of Phase Change Materials
Scope: PCMs are critical to keeping temperature of insulated packages

constant throughout the entirety of the packages journey. They are needed to
ensure contents arrive within acceptable temperature ranges. The time and
melting point of PCMs in each insulating container is to be determined.
Materials: PCMs, container, water, freezer, scale, temperature logger, timer.
Method: Fill container with large enough to hold PCMs. The container, water
and PCM are weighed individually. Condition water in test environment for 24
hours prior to beginning test while simultaneously freezing the PCMs. After 24
hours, the PCMs are quickly submerged into the conditioned water.
Temperature logger is placed inside the container. The beginning and lowest
water temperature is recorded.
Duplicate of test is carried out with average results presented.
Latent heat is then calculated from the heat balance as per Singh et al., 2007:
Heat lost by water = Heat gained by PCM
5.4. Temperature Monitoring with Phase Change Materials
Scope: Monitor the internal temperature of insulated packages for 24 hours to

determine the length of time at which the contents remain below 8°C with the
inclusion of phase change materials.
41
Materials: Insulated packages, dummy packages, phase change materials, temperature
logger, timer, hydrometer, freezer, packaging tape, storage area.
Method: 2 Dummy packages are placed in fridge and 2 PCMs are placed into freezer
for 24 hours. After 24 hours, remove items and pack into insulated packages
and seal as per manufacturers recommendations as. Place temperature
loggers into packages as well as between dummy packages to record
temperature of substitute products as described in Figure 21. Store in area
with constant ambient temperature. After 24 hours, open box and review
temperature data to determine length of time package and contents remained
below 8°C. Undertake test for each insulated package.
5.5. Temperature Monitoring without Phase Change Materials
Scope: Monitor the internal temperature of insulated packages for 24 hours to

determine the length of time at which the contents remain below 8°C without
the use of phase change materials.
Materials: Insulated packages, dummy packages, temperature logger, timer, hydrometer,

freezer, packaging tape, storage area.
Method: Dummy packages are placed in fridge for 24 hours. After 24 hours,
remove items and pack into insulated packages and seal as per
manufacturers recommendations. Place temperature loggers into packages as
well as between dummy packages to record temperature of substitute
products. Store in area with constant ambient temperature. After 24 hours,
open box and review temperature data to determine length of time package
and contents remained below 8°C. Undertake test for each insulated package.
5.6. Water Vapor Transmission Rate of Novel Packaging Material
Scope: Determine the rate at which water vapor passes through an area of
insulating package film material according to ASTM F1249 - Water Vapor
42
Transmission Rate Through Plastic Film and Sheeting Using a Modulated
Infrared Sensor for Plastics.
Materials: Desiccant, absorbent pads, distilled water, film samples, sealant, nitrogen gas,
PERME® C390 Water Vapor Transmission Rate Test System (Labthink
International, Inc., USA).
Method: Cut film samples to be tested to appropriate size and measure

thickness at four equally spaced points and in the middle of the specimen.
Grease the sealing surface. Follow WVTR test system to set humidity and
temperature. Affix the film to the diffusion cell. Measure WVTR as
manufacturers instructions.Relative humidity (RH) and the record temperature
of each test as temperature is critical to WVTR.
WVTR is calculated as per ASTM F1249-13:
WVTR = C (ES - EO)

Where:
C = calibration factor expressing rate as a function of voltage (or mV).
EO = permeation system zero level voltage
ES = equilibrium voltage obtained with the test specimen
Otherwise on new test system, WVTR is calculated automatically.
The unit for WVTR is g/m2.d
5.7. Monitored Delivery
Scope: Assess the effectiveness of insulating packaging materials during

delivery by subjecting them to an actual use case.
Materials: Insulated packages, scale, phase change materials, temperature sensitive

dummy packages, scale, temperature logger, packaging tape, logistics
handler.
Method: Place PCMs in freezer for 24 hours and dummy packages in

refrigerator for 24 hours prior to beginning test. At time of testing, place
temperature logger was placed between 2 dummy packages which were then
43
placed between 2 freezer packs as shown in Figure 21. The contents were
then held together with 2 rubber bands so as to not influence the way in which
insulating materials performed in their ability to maintain temperature. The
entire set up was then placed into the shipping boxes. Additional temperature
logger was placed on the outside of container to record external temperature
conditions. This was then repeated for each of the insulating packages. Boxes
were then taken to the Austrian postal service in Favoriten, Vienna where they
were paid for at the self service counter. Goods were delivered to Linz where
upon arrival, each package was open to inspect quality of internal goods.
Internal and external temperatures were constantly measured to determine
quality of insulating material after undergoing transit from one location to
another.
Figure 21: Package Experiment Assembly.
44
6.0. Results
1kg of water was frozen for 24 hours before testing was set in the test area for 30
minutes to condition before been placed in container and sealed into each insulating
package. At the end of the test period, the remaining ice was removed and remaining water
weighed. This process was repeated twice for each insulating material and the average
results summarised in Table 3. Detailed collection of results is available in Appendix 1 -
Detailed Results. This was then used to calculate the R-values as per the equation in section
5.1.
Temperature difference = ambient temperature - melting point of ice as defined in

Singh et al., 2007.
Average ambient temperature of test area = 22.3°C.
Melting point of ice = 0°C.
Temperature difference = 22.3°C.
1 kg of regular ice must absorb 334kJ of heat to melt as defined in Legates, 2005.
Latent heat of ice = 334kJ.
Surface Avg. Melt rate Avg. R-values

Insulated Container System
Area (m2) (kg/hr) (m2°C/W)24h
Österreich Post AG Paket Box Large with EPS Inlays 0.36 0.031 0.77
Österreich Post AG Paket Box Large with Landpack Landbox 0.38
0.028 0.93
Hemp liner
Österreich Post AG Paket Box Large with Woolcool Fleece 0.35
0.023 1.00
Liner
Österreich Post AG Paket Box Large with Supaso Ecoliner 0.39 0.017 1.11
Table 3: Properties to Calculate Average System R-Value of Insulated Container Systems.
The Supaso Ecoliner reported the highest average R-value, which suggests that it
has performs the best at resisting heat penetrating the system and affecting the contents.
45
2 x 1kg Supaso ice packs were frozen for 24 hours before been placed into each
insulated package. A tive tag temperature monitor was placed between the 2 PCMs and
were wrapped in aluminium foil to prevent heat loss. Melting was observed on the time
versus temperature plot as the flat part of the curve.
Ice packs were placed into the EPS box at 14:29 on 04/08/2023. The initial
temperature was -18.95°C. Temperature of the ice pack reached above zero at 16:38
05/08/2023. The length of the packs remained frozen was 1 day 2 hours 9 min as seen in
Figure 22.
Figure 22: Melting Point of PCMs in EPS Inlays.
46
PCMs remained frozen in the Landpack Landbox Hemp package for a total of 1 day
and 35 minutes, from 14:35 04/08/2023 until 03:10 05/08/2023 as shown in Figure 23.
Figure 23: Melting Point of PCMs in Landpack Landbox Hemp.
47
The PCMs in the Woolcool Fleece Liner package remained below 0°C from 14:30
04/08/2023 until 19:01 06/08/2023 for a total of 2 days 4 hours and 34 minutes as shown in
Figure 24.
Figure 24: Melting Point of PCMs in Woolcool Fleece Liner.
48
The Supaso Ecoliner package was able to maintain PCM temperature below 0°C
from 14:31 04/08/2023 until 19:16 06/08/2023 for a total of 2 days 4hours and 45 minutes as
shown in Figure 25. However, it is possible this may have lasted longer but the experiment
was ended at this time due to time constraints and was when the package was opened to
monitor temperatures recorded by the tive tag.
Figure 25: Melting Point of PCMs in Supaso Ecoliner.
49
The total length of time at which insulated packages were able to keep the PCMs
below 0°C is presented in Table 4 and Figure 26.
Figure 26: Melting Point of PCMs Comparison.
50
In this experiment, each insulating material demonstrated its ability to resist heat, by
insulating the PCMs and prolonging their solid, frozen state. As the PCMs are filled with
water, the melt temperature is measured when the PCM reached above 0°C. As can be seen
in Table 4, the ice packs were between -19°C and -17°C while the PCM placed into the
Supaso package was -14°C. Both the Landpack Landbox Hemp and EPS Inlays lasted a
little over 24 hours in regards to the frozen state of PCMs. Packages containing the
Woolcool Fleece Liner and the Supaso Ecoliner lasted well over 2 days in keeping the PCMs
below 0°C. However, where the Woolcool Ecoliner Reached 0.01°C after this period, the
Supaso Ecoliner was still below 0°C at the end of the test period. Leaving the contents for a
longer period of time may have resulted in prolonging the below 0°C state of the PCMs.
Landpack
Woolcool Fleece
EPS Inlays Landbox Supaso Ecoliner
Liner
Hemp
Start Date 4-Aug 4-Aug 4-Aug 4-Aug
Start Time 14:29 14:35 14:30 14:31
Start Temp. (°C) -18.95 -16.65 -16.65 -16.86
Ext. Temp. (°C) 21.0 21.0 21.0 21.0
Humidity (%) 73 73 73 73
End Date 5-Aug 5-Aug 6-Aug 6-Aug

End Time 16:38 3:10 19:01 19:16
End Temp.(°C) 0.01 0.01 0.01 -0.24
Ext. Temp. (°C) 20.1 20.1 20.1 20.1
Humidity % 72 72 72 72
Temp. Change (°C) 18.96 16.66 16.66 13.62

Time Below (°C) 1 day 2 hours 9 min 1 day 35 min 2 days 4 hours 34 min 2 days 4 hours 45 min
Hours Below (°C) 26.16 24.58 52.56 52.75
Table 4: Melting Point PCMs in Insulated Containers - Comparison
51
The latent heat of a PCM is the energy absorbed during the change in phase from
solid to liquid. According to Legates, D.R (2005), the known latent heat of water is 334kJ/kg.
Figure 27 shows the average temperature curve as the frozen PCM and water reach
equilibrium.
Figure 27: Latent Heat Experiment Results - Average.
As only 1 type of PCM was used throughout the experiments of this thesis, (Supaso
Frozen Ice Pack) 2 samples were tested with the average results recorded as demonstrated
in Table 5. Both PCMs were placed into containers of water and the temperatures reached
their lowest point 65 minutes after submersion into 8L of water in two 10L buckets. This is
where the water is temperature is at its lowest before it begins to raise to the temperature of
the room again. Simultaneously, this is the point where the PCM begins to match the
temperature of the water. A point of equilibrium is reached.
Information regarding the experiment is presented in Table 6. The average heat lost
by the water sample is 11.07°C while the average heat gained by the PCMs is 30.4°C. This
is calculated as per the calculation defined by Singh et al., (2007) as the heat loss
experienced by water is equal to the heat gained by the PCM.
52
Average Water Temp. Time after Submersion
Date Time
(°C) (Minutes)
3/08/2023 10:46:45 19.46 0
3/08/2023 10:51:46 19.33 5
3/08/2023 10:56:48 18.20 10
3/08/2023 11:01:49 13.57 15
3/08/2023 11:06:51 12.07 20
3/08/2023 11:11:52 10.94 25
3/08/2023 11:16:54 10.56 30
3/08/2023 11:21:56 9.81 35
3/08/2023 11:26:57 9.55 40
3/08/2023 11:31:59 9.42 45
3/08/2023 11:37:00 9.05 50
3/08/2023 11:42:02 8.78 55
3/08/2023 11:47:03 8.66 60
3/08/2023 11:52:05 8.39 65
3/08/2023 11:57:07 8.39 70
3/08/2023 12:02:08 8.39 75
3/08/2023 12:07:10 8.53 80
3/08/2023 12:12:11 8.53 85
3/08/2023 12:17:13 8.66 90
3/08/2023 12:22:15 8.78 95
3/08/2023 12:27:16 8.91 100
Table 5: Latent Heat Experiment Results - Average.
Date 2/08/2023
Time 10:39 16:45
Room Temp. (°C) 20.8 20.9
Humidity (%) 76 74
Freezer Temp. (°C) -22
Known Latent Heat Water (kJ/kg) 334
PCM 1 PCM 2
Weight (g) 1,033 1,033
Bucket (g) 742 744
Starting Water Temp. (°C) 19.33 19.58
Lowest Water Temp. (°C) 8.25 8.53
Time 11:52 11:51
Minutes 65 65
Heat Lost by Water (°C) 11.08 11.05
Heat Gained by PCM (°C) 30.25 30.53
Table 6: Information Latent Heat Experiment.
53
Monitoring of the EPS Inlay package showed a gradual increase in temperatures of

the internal temperature and package temperature over the 24 hours period. With an external
temperature around 20°C the EPS Inlay package demonstrated its ability to keep the dummy
package below 3°C for 24 hours. Internal temperature of the package demonstrated a
gradual rise over the test period as shown as can be seen in Figure 28.
Figure 28: 24 hour Temperature Monitoring with PCMs - EPS Inlays.
54
The Landpack Landbox Hemp was able to maintain a constant internal temperature
for 10 hours before the temperature began to rise. However, this temperature rise had no
effect on the dummy packages which remained around the 0°C for the entirety of the test
period as shown in Figure 29.
Figure 29: 24 hour Temperature Monitoring with PCMs - Landpack Landbox Hemp.
55
The internal package temperature of the Woolcool Fleece Liner was not able hold a
constant temperature over the monitoring period. Having reached a low of 5°C, which was
the highest of the low interior package temperatures and rising ever so slightly after the first
hour, the package temperature was able to maintain relatively constant despite this as can
be seen in Figure 30.
Figure 30: 24 hour Temperature Monitoring with PCMs - Woolcool Fleece Liner.
56
After reaching the lowest internal and dummy package temperatures, the Supaso Ecoliner
demonstrated the ability to keep temperatures for the remaining 24 hours of monitoring as
can be seen in Figure 31
Figure 31: 24 hour Temperature Monitoring with PCMs - Supaso Ecoliner.

.
57
While the average external temperature floated around 19°C throughout the test period, the
average internal temperature was exceeded to the magnitude of several degrees by the
Woolcool Fleece Liner. The Landpack Landbox Hemp demonstrated that it was able to hold
the internal temperature cooler for longer, while EPS Inlays and the Supaso Ecoliner
performed in a very similar manner over the test period with the internal temperature of all
materials rising to around experienced by all the insulating materials experienced a constant
rise in temperature to 9°C after 24 hours as shown in Figure 32.
Figure 32: 24 hour Temperature Monitoring with PCMs - Interior Insulating Material Comparison.
58
Figure 33 shows that when displayed together, the dummy package located in each
material showed a very similar decrease in temperature over the monitoring time. At no point
in the 24 hour monitoring period did the dummy packages reach 8°C. All the dummy
packages maintained a constant temperature, except for the EPS Inlay which continued to
show a fall in temperature after around 22 hours.
Figure 33: 24 hour Temperature Monitoring with PCMs - Package Comparison.
59
Temperatures in Table 7 identify the highest and lowest average exterior, interior and
dummy package temperatures over a 24 hour monitoring period. The Woolcool Fleece Liner
displayed both the highest interior temperature as well as the coldest dummy package
temperature while also experiencing the highest low temperature inside any of the boxes.
The Supaso Ecoliner demonstrated the coldest interior temperature of all the insulating
materials while EPS Inlays performed better than the other materials in that it showed the
lowest of the highest temperatures experienced inside the insulated boxes while the package
inside the Landpack Landbox Hemp insulated box.
Material Location High Temp. Time Low Temp. Time

(°C) (°C)
EPS Inlays Exterior 19.33 08:46 (01/08) 18.70 03:17 (02/08)
Interior 9.92 06:28 (02/08) 4.41 08:51 (01/08)
Package 13.07 08:46 (01/08) -0.24 10:31 (01/08)
Landpack Landbox Hemp Exterior 20.33 08:44 (01/08) 18.70 05:19 (02/08)
Interior 10.03 08:20 (02/08) 4.53 08:59 (01/08)
Package 17.20 08:44 (01/08) -0.12 07:00 (01/08)
Woolcool Fleece Liner Exterior 20.33 08:46 (01/08) 18.7 05:58 (02/08)
Interior 17.45 08:46 (01/08) 5.16 09:01 (01/08)
Package 12.74 08:46 (01/08) -0.48 10:51 (01/08)
Supaso Ecoliner Exterior 19.99 08:42 (01/08) 18.74 05:55 (02/08)
Interior 15.2 08:42 (01/08) 2.60 13:09 (01/08)
Package 13.32 08:42 (01/08) -0.12 12:19 (01/08)
Table 7: Temperature ranges 24 hour Monitoring with PCMs.
60
Temperature monitoring of the EPS Inlay package showed a gradual balancing of

temperatures over the 24 hours of monitoring. The early peak temperature experienced by
the dummy packet was followed by a sharp decrease in temperature before leveling out at a
constant rate over the preceding day. Exterior temperature experience by the package was
relatively constant throughout the time of monitoring as can be seen in Figure 34.
Figure 34: 24 hour Temperature Monitoring without PCMs - EPS Inlays.
61
The Landpack Landbox Hemp package displayed a relatively smooth temperature
exchange over the 24 hours of monitoring. Lowest dummy package temperature was
experienced very early in the monitoring as well as a slight decrease in internal temperatures.
The average exterior temperature remained relatively constant and throughout the 24hour
monitoring period, internal temperature and temperature of the dummy package were close
to been balanced as shown in Figure 35.
Figure 35: 24 hour Temperature Monitoring without PCMs - Landpack Landbox Hemp.
62
Woolcool Fleece Liner temperatures tracked in a smooth parabolic manner over the
course of the monitoring period. Temperatures of the interior package and the dummy
package experienced a slight increase in temperature over the same period as shown in
Figure 36.
Figure 36: 24 hour Temperature Monitoring without PCMs - Woolcool Fleece Liner.
63
Internal and dummy packet temperatures experienced a constant, yet gradual rise
over the monitoring period. Exterior temperature remained relatively constant as shown in
Figure 37.
Figure 37: 24 hour Temperature Monitoring without PCMs - Supaso Ecoliner.
64
While the average external temperature fluctuated within 1°C throughout the
monitoring period, the internal temperature experienced by all the insulating materials
experienced a constant rise in temperature to come to a similar temperature as shown in
Figure 38. Each material showed an early decrease in temperature before reaching the
lowest temperature within an hour of the beginning of the experiment before slowly rising
towards a balance of the external temperature.
Figure 38: 24 hour Temperature Monitoring without PCMs - Interior Insulating Material
Comparison.
65
Figure 39 shows that when displayed together, the dummy package located in each
material showed a very similar increase in temperature over the monitoring time. Early on
each packet displayed a sharp decrease in temperature before leveling out over the 24 hours
they were monitored.
Figure 39: 24 hour Temperature Monitoring without PCMs - Package Comparison.
66
Temperatures in Table 8 identify the highest and lowest average exterior, interior and
dummy package temperatures over a 24 hour monitoring period. EPS Inlays displayed both
the highest dummy package temperature as well as experiencing the lowest internal
temperature. Over the monitoring period, Landpack Landbox Hemp was able to display the
lowest temperature experienced by the dummy package while the Woolcool Fleece Liner
demonstrated the highest internal temperature experienced by all of the insulating materials.

(°C) (°C)
Interior 19.83 14:09 (26/07) 17.57 23:50 (25/07)
Package 19.33 23:06 (26/07) 13.45 23:40 (25/07)
Interior 19.71 23:32 (25/07) 18.20 00:22 (26/07)
Package 18.58 21:58 (26/07) 13.32 23:37 (25/07)
Interior 20.20 23:38 (25/07) 18.20 00:23 (26/07)
Package 18.71 20:5 (26/07) 13.95 23:38 (25/07)
Interior 19.71 23:39 (25/07) 17.95 00:49 (26/07)
Package 18.96 21:51 (26/07) 13.95 23:39 (25/07)
Table 8: Temperature ranges 24 hour Monitoring without PCMs.
67
WVTR test was undertaken on the Supaso Ecoliner only. This was due to the fact
that the Woolcool Fleece Liner consists of a perforated film and the Landpack Landbox
Hemp film is constructed from a permeable PLA material. As the Supaso Ecoliner was the
only insulating material to be constructed from a noon-permeable material, it was the only
sample subject to the WVTR test.
Cell T (°C) RH (%) WVTR (gr/m2.24h)

a 12 90 0.689
b 12 90 0.721
c 12 90 0.758
Table 9: WVTR for Supaso Ecoliner Samples at 12°C / RH 90%.
Cell T (°C) RH (%) WVTR (gr/m2.24h)

a 38 90 5.807
b 38 90 6.073
c 38 90 6.768
Table 10: WVTR for Supaso Ecoliner Samples at 38°C / RH 90%.
The test was undertaken at a “worst case” scenario in that the RH was set to 90%.
Test with a hand held hydrometer placed into the Supaso Ecoliner package showed RH
between 71 and 74% in experiments where ice packs were inserted into the package. The
temperature of 38°C also exceeded temperatures likely to be experienced inside the
package, where as the 12°C temperature was the minimum temperature to which the WVTR
test system could be set at (although the actual temperature during the test was recorded to
be between 15 and 16°C.
As shown in Table 9 and 10, the HDPE film demonstrated that even in the worst case
scenario, only small amounts of water which may appear due to condensation or melting of
packaged products, will go on to permeate through the film and impact the cellulose material.
At RH of 90% and temperature of 12°C only 0.758g of water per square meter of
material is able to penetrate over a 24 hour period while at the higher temperature of 38°C
6.768 grams would ultimately penetrate the film.
68
Packages for delivery were prepared in the laboratory of the Packaging Department
of the FH Campus Wien. Once ready for shipment, they were brought to the Österreichische
Post AG center at Favoriten where they were sent into the delivery through the self service
counter. Each item was weighed and cost for delivery was according to the dimensions and
weight of the package. Weights cost of each package can be seen in Table 11.
Package Weight (g) Cost (€)

EPS Inlays 3,650 8.00
Landpack Landbox Hemp 4,400 11.44
Woolcool fleece inlay 3,830 8.00
Supaso Ecoliner 4,810 11.44
Table 11: Package Information from Österreichische Post AG.
Packages were placed into the Österreichische Post AG parcel system on

19/07/2023 at 17:20. According to historical temperature data, the temperature recorded in
Vienna at this time was approximately 32.8°C and having spent a total of 1 day, 14 hours
and 15 minutes in the Austrian postal system. Upon delivery to Linz on 21/07/2023 at 07:35,
the historical temperature at this time was 16.1°C.
EPS Inlays demonstrated a reduction in internal temperature as the external
temperature began to rise. When the external temperature reached its peak, the internal
temperature rose sharply which correlated with a rapid increase of the package temperature
as shown in Figure 40.
Figure 40: Temperatre Profiles EPS Inlays.
69
As the Landpack Landbox Hemp experienced a steep rise in temperature, the interior
temperature dipped and even experienced the lowest internal temperature despite
experiencing the highest external temperature. As such, the package began to rise in
temperature at a steady rate until reaching a similar temperature to he internal temperature
when the box was delivered and opened to inspect the contents as can be seen in Figure 41.
Figure 41: Temperatre Profiles Landpack Landbox Hemp.
As the exterior temperature of the Woolcool package reached its highest point, the
interior temperature dropped sharply before continuing on a slightly upward trajectory.
However, as the exterior temperature reached its peak, the package contents made a sharp
increase in temperature up to the point when delivery of the package was accepted as
shown in Figure 42 with highest and lowest temperatures experienced as shown in Table 12.
Figure 42: Temperature Profiles Wolcool Fleece Liner.

70
The highest interior temperature experienced by the Supaso package was correlated
with the highest interior temperature. Surprisingly, the temperature of the package remained
relatively stable despite the changing temperature of the package. Range of temperatures
experienced by the package insulated with the Supaso Ecoliner are shown in Figure 43 and
Table 12.
Figure 43: Temperature Profiles Supaso Ecoliner.
Figure 44 shows that the internal temperature profiles for all insulating materials
demonstrated rising internal temperatures before experiencing drops in temperature before
rising again. While EPS Inlays demonstrated the sharpest and highest rise in internal
temperature, the Supaso Ecoliner began to cool again until slightly rising before the package
was delivered. Both the Landpack Landbox Hemp and Wool fleece liner demonstrated drops
in temperature before demonstrating parabolic rise in temperature.
Figure 44: Internal Temperature Profiles Insulating Materials.

71
Figure 45 demonstrates each insulating materials ability to keep the dummy package
cool. As can be seen, each graph demonstrated that once placed into the boxes, the cool
packs brought the temperature of the dummy packages down several degrees. EPS Inlays,
Woolcool Fleece Liner and Landpack Landbox Hemp show that temperature raises
considerably after approximately 24 hours, whereas the dummy packages inside the Supaso
Ecoliner experiences a slight raise in temperature, but trends down after the 24 hour mark.
Figure 45: Package Temperature Profiles.
72
Table 12 describes the highest and lowest temperatures experienced by the
packages as they were processed through the Österreichische Post AG system. The Supaso
Ecoliner demonstrated the ability to reach the coldest internal temperature of all the
packages. The EPS Inlays recorded both the highest and lowest temperatures experienced
by the dummy packages while the Woolcool Fleece Liner internal temperature was several
degrees hotter than the next package.

(°C) (°C)
Interior 17.82 07:31 (21/07) 5.16 16:30 (19/07)
Package 14.57 07:31 (21/07) -0.24 18:28 (19/07)
Interior 14.32 07:34 (21/07) 7.75 17:46 (20/07)
Package 13.07 06:53 (21/07) -0.24 18:00 (19/07)
Interior 18.58 07:35 (21/07) 11.81 18:37 (19/07)
Package 13.57 07:00 (21/07) 0.54 18:12 (19/07)
Interior 4.66 17:25 (20/07) 0.01 17:22 (19/07)
Package 1.32 17:30 (20/07) 0.01 17:52 (19/07)
Table 12: Temperature Ranges Experienced Throughout Delivery.
73
7.0 Discussion
This research investigated the use of novel materials as thermal packaging solutions
for use in cold chain logistics and compared them to a conventionally available and widely
used material in cold chain shipments (EPS). Several experiments were undertaken to
assess the suitability of materials in a number of different use cases. First, the R-value for
each package system was calculated. This is the ability for a material to resist temperature,
and is important for shipping temperature sensitive goods as it will determine how long the
contents stay within their acceptable temperature range.
In order to keep packages cold throughout the journey from production, dispatch and
ultimately to the end consumer, PCMs are used to help reduce package temperature. To
determine the effectiveness of water based PCMs, the melting point and latent heat
absorption was tested to determine their effectiveness for use with insulating packaging
materials.
The next tests were undertaken to determine the temperatures experienced by
dummy packages both with and without the inclusion of PCMs included in the packaging
materials.
Additionally, packaging materials will experience some amount of moisture build up
throughout their journey as PCMs ultimately melt and cause the build up of moisture and
condensation in the package. Therefore the WVTR of novel insulating materials was tested
to determine if they were able to keep the inside materials dry.
Finally, an actual use case was undertaken where dummy packages were kept cool
with PCMs and sent via the postal system from one place to another and the effectiveness of
the insulating materials determined.
74
A materials R-value refers to its ability to resist the transfer of heat energy. This is of
significant importance in cold chain logistics as the thermal performance of insulating
materials will influence how much, and what type of material is needed to protect a packages
contents from heat experiencing heat damage.
4 materials were tested, each containing a known amount of ice placed into the
system consisting of a postage box and insulating materials. The packages were left for 24
hours and the melted ice collected and weighed to determine the melt rate.
The Supaso Ecoliner recorded the lowest melt rate as well as the highest R-value of
all the materials. The Woolcool Fleece Liner and Landpack Landbox Hemp performed very
similar in regards to the ice collected at the end of the test periods and also R-values within a
small range of each other. The EPS Inlays performed the worst of all the materials.
One reason for the Supaso Ecoliner performing relatively well in this regard is due to
the relatively moderate density yet low thermal conductivity of recycled paper, from which the
insulation is made. This means more material can be inserted into each package and
therefore resist more heat from entering into the package.
Despite hemp having a lower thermal conductivity when compared to paper, as well
as having a higher density, the Supaso Ecoliner was able to demonstrate a higher insulating
value, due in part to the greater thickness of the insulating package. The average thickness
of Landpack Landbox Hemp is 20mm, for the Woolcool Fleece Liner is 25mm, for EPS is
20.1mm while the Supaso Ecoliner had an average thickness of 40mm, which is almost
double the amount of material than any other insulating material. As proposed by Kallioğlu et
al. (2019), one of the most important factors affecting the transfer of heat through a material
is its thickness. As the amount of insulation material in use is increased, so too is the thermal
resistance.
The further distance that heat has to travel in order to reach an item, the more likely it
is to dissipate, or experience resistance before been absorbed by an object inside the
insulated package.
75
PCMs are integral to keeping a packages contents within the required temperature
range. This helps maintain freshness and suitability of a product until the point at which it is
to be consumed.
The Supaso Ecoliner demonstrated its abilty to keep PCMs below 0°C for the longest
by maintaining the temperature below 0°C for over 52 hours while also experiencing a
temperature change of 13.62°C over this time frame. The Woolcool Fleece Liner also kept
the temperature of the PCMs below 0°C for over 52 hours, however the beginning
temperature of the PCMs were -16.65°C whereas those that were insulated by the Supaso
Ecoliner was almost 3°C less at -13.86°C.
PCMs placed into Woolcool Fleece Liner and Landpack Landbox Hemp insulation
were the same temperature of -16.65°C however the PCMs in the Landpack Landbox Hemp
package were only able to maintain temperature below 0°C for just over one day, less than
half the time of the Woolcool Fleece Liner. The temperature change was 16.66°C over the
24.6 hours that the items stayed below 0°C in the Landpack Landbox Hemp container.
The EPS Inlay was able to perform moderately better than the Landpack Landbox
Hemp insulation in that it kept the PCMs frozen for 1 day and 2 hours, 1 and a half hours
longer, however the starting temperature was also 2°C colder. Therefore a temperature
change of 18.96°C was experienced over this time frame and may be able to explain the
longer period of time that the contents were below 0°C.
This experiment demonstrated the important role PCMs play in the delivery of
temperature sensitive products and the ability of each material to do so. While these results
were calculated using just 2 PCMs, it would be interesting to see how the results would
change if there were to be more PCMs inserted into the insulating materials. However, the
amount of PCMs will also affect the weight of the overall package in order to keep
temperatures colder for longer. Should the package be dispatched and delivered to the end
customer in a short time period and in different climatic and temperature conditions, then the
total number of PCMs used may be different from the results obtained here.
EPS Inlays, Woolcool Fleece Liner and Supaso Ecoliner all experienced a sharp rise
in temperature from the frozen state until below 0°C while the Landpack Landbox Hemp
container exhibited a slower increase in temperature. However Landpack Landbox Hemp
was the first package to reach above 0°C followed by EPS Inlays, Woolcool Fleece Liner and
then Supaso Ecoliner. As demonstrated in experiment 7.1, the thickness of a material will
determine the rate at which heat enters a package and influences the internal contents.
The lower thermal conductivity of hemp (0.0146 - 0.0356 W/m°C) and higher density
(0.86 - 1.6 g/cm3) would suggest that the LandPack LandBox Hemp container would remain
cooler for a longer period of time. However, in this instance, it was not the case. This could
76
be due to the manner in which the hemp material has been used in the insulating package.
Although experiencing the highest density of the 4 materials, the material may not be densely
packed as the others. The relatively low thickness of the material (20mm average) and
ununiformity of the packaged fibers may allow for the passage of heat into the internal
package.
Although experiencing a colder low temperature (-19°C) compared to that of the
remaining materials (-16.8°C) the PCMs in the container of EPS Inlays displayed the second
shortest time at keeping the PCMs below 0°C, This can be attributed to the low density of the
material and the large amount of air in the containers. Unlike the other materials, the EPS
Inlays are rigid and do not envelope the contents. This allows for the air in the container to
take on heat which passes through the EPS Inlays to begin warming and then transfer heat
to the PCMs quicker than experienced by the remaining materials.
The Woolcool Fleece Liner and Supaso Ecoliner exhibited much longer times in
which the PCMs remained below 0°C. with a relatively similar thermal conductivity and ability
to envelope the PCMs in the container contributed to the prolonged time under 0°C. While
wool has a density of 1.307g/cm3 compared to papers density of 0.238g/cm3, the thickness of
the Supaso Ecoliner (which is almost double of the Woolcool Fleece Liner) is what enabled a
greater resistance to thermal influence from outside of the container.
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Legates, D.R. (2005) describes latent heat of as the energy required to melt 1g of ice
at 0°C, which is 334J. This means that when water is in its liquid state, it has 334J/g more
energy than of water in its frozen state at the same temperature.
Latent heat can therefore be described as a “form of internal potential energy stored
by water”. When ice begins to melt, the molecules change their state from solid to liquid while
this energy required to change their state does not result in a change in temperature. Rather,
this gets stored through the changing state of the water molecules. This change in energy is
termed latent heat as it does not change the temperature of the water molecules and
thermometers are unable to measure this change in energy.
Latent heat is particularly useful to know as it can help to determine the amount of
PCMs required to keep an sensitive item at a certain temperature in a particular environment
over a duration of time.
As only one type of PCM was used throughout the experiments performed in this
thesis, there is no other results to compare to which can help to determine what PCM
perform the best under which conditions. Instead, as the latent heat of water is know, the
temperature difference of both the buckets of water and the PCMs themselves were
recorded.
Water in the bucket equalized temperature after 65 minutes from the placement of the
PCM. This suggests that both the PCM and the water in the bucket reached the same
temperature before beginning to reach equilibrium with the temperature of the test area. With
a starting temperature of 19°C the water experienced a temperature loss of 11°C while the
PCM which was placed in the freezer at -22°C for the experiment can be said to have gained
temperature of 30°C in order to reach a stabilizing temperature with its surroundings as it
absorbed heat from the water.
This experiment demonstrates the manner in which a PCM can be influenced from its
surrounding environment. Should a shipment be packaged with many more PCMs, then the
likelihood that the contents stay cooler for longer will also increase. Inversely, the use of
PCMs inside a container will also affect the conditions experienced inside the package. As
the water and PCMs begin to stabilize in temperature before beginning to reach equilibrium
with their surrounding environment, this demonstrates their importance in the shipment of
temperature sensitive products.
78
After 24 hours, the dummy packages in all the insulated boxes were around 0°C,
except for the EPS Inlay box, where the internal package had reached close to 2.5°C. This
shows that with the inclusion of even a small amount of PCMs (2 - one on top and bottom)
that they were able to effectively keep the contents a or below 0°C for a prolonged period of
time.
Should the temperature of the contents need to stay colder for longer, more PCMs
could be added, however this may have an impact on the quality of the contents if falling
below 0°C were to damage the contents.
The EPS Inlay package continued to cool over the dummy packages over 24 hour
period displaying inverted peaks as the trajectory of the temperature continued downwards.
The dummy package in the EPS Inlay box took longer to cool down than what was
experienced with the other materials, but was continuing the trajectory in the negative
direction while the dummy package of the remaining materials was beginning to increase at
the end of the 24 hours.
With regards to the Landpack Landbox Hep material, after the dummy package
began to adsorb the cool temperature, it maintained a temperature close to freezing for 22
and a half hours. It also began to get cooler dipping below 0°C towards the end of the 24
hours. The interior temperature experienced a rapid dip in temperature before maintaining
the same level for 11 hours before beginning to rise again to 10°C degrees at the end of 24
hours despite external temperature remaining constant.
The Woolcool Fleece Liner package remained under 0 for 9 hours before rising
before the end of the monitoring period. Despite hitting an early low temperature, interior
temperatures began to constantly rise over 24 hours with top internal temperature rising to
10 degrees despite the external temperature showing a downward tend over the 24 hour
monitoring period.
Supaso Ecoliner was the best performing package with interior temperatures rising
and falling just above and below zero for the duration of the monitoring period. Internal
temperature was trending slightly up at the end of the period while the dummy packages
remained at a constant temperature after absorbing the cool from the PCMs.
These results may be attributed to the fact that each of the insulating materials are
not rigid and envelope the contents better than those inside the container with the EPS
Liners. It seems as though the added material would make it harder for the air inside the
package to interact with the contents and influence the temperature profile, by absorbing the
air temperature from the testing room. Additionally, the higher density and material thickness
make it harder for heat energy to travel into the package and influence the contents.
79
Although the EPS Inlays, Supaso Ecoliner and Woolcool Fleece Liner have similar
thermal conductivities (0.036, 0.037 and 0.038W/mK respectively) material thickness and
densities is the remaining factors which influence the rate at which temperature reaches the
contents inside the containers.
80
A test was undertaken to determine how a thermal package maintains its temperature
without the inclusion of PCMs in order to keep the contents of the package cool. As is seen
in the time/temperature graphs, each insulating package, without the inclusion of PCMs, is
subject to the external temperature it is experiencing. It can be seen in all materials that the
internal and external temperatures track in relatively the same shape. As the exterior
temperature raises the interior temperature of the package, this corresponds to an increase
of the temperature of the dummy package inside. However, unlike the interior and exterior
time/temperature graphs which followed the same path, the graphs of the dummy packages
traveled in a parabolic trajectory. This is likely to do with the fact that the dummy packages
will continue to take take on the temperature of the box until they reach equilibrium. This may
have happened if the test period was allowed to continue for 48 hours, instead of 24.
What was interesting in this scenario, is that the EPS Inlay package exhibited the
lowest interior temperature, while also experiencing the highest temperature of all the dummy
packages. The temperature at which the dummy package reached its highest point was only
half a degree away from the highest temperature recorded inside the package and was very
close to reaching the the highest temperature recorded on the exterior of the package. This
suggests that the EPS Inlay is not effective at resisting heat when there is no mechanism to
keep the interior contents cold. The Landpack Landbox Hemp package experienced the
coolest temperature of all dummy packages, followed by the EPS Inlay package with the
highest temperature recorded by both the Woolcool Fleece Liner and the Supaso Ecoliner
package. The Woolcool Fleece Liner recorded the highest interior temperature.
This results of this experiment can be shown to suggested that if a package was to be
delivered in a high heat, the inside contents will very quickly take on the temperature of the
outside environment if PCMs are not present, or they have not been installed properly. It
highlights the important role they play in maintaining the internal package temperature which
has a great effect on the temperature of the contents.
81
WVTR is the rate of water vapor passing through a material of a certain area at a
certain temperature and humidity over a 24 hour period. This is important to know especially
as packaged goods or PCMs begin to change temperature, condensation and moisture is
likely to build up inside a package. Moisture can go on to affect the contents of the package,
or affect the materials which are used to create the insulating materials.
In some regards this may be favourable, in others it may not without specifying the
type of product been shipped. If the item to be sent must remain dry, then it would be
favourable for the WVTR of the insulating material to be higher, allowing moisture to be
absorbed by the insulating materials and taken away from the contents. However, if this is
not necessary, then a little bit of moisture left to remain inside the package may be desirable.
However, any excess moisture that may escape to the box the item is shipped in may
become moist or wet and cause the contents to no longer remain contained in the box, or it
may be damaged due to excessive moisture build up. For the case of frozen/chilled food
delivery, a small amount of moisture inside the package may not be of concern to the end
customer. However, depending on the length of time for the package to reach the end
consumer, this build up of moisture may lead to the development of mold or any other
undesirable contaminants that exist in water.
It is not known if the presence of excess moisture inside the package is beneficial to
keeping the contents cool. This was not tested as part of this experiment, however, it can be
assumed that if moisture is present inside the package, that it may be influenced by external
temperatures easier than a frozen PCM which will begin to influence the melting rate of the
PCMs inside the container.
Made from HDPE, the Supaso Ecoliner was able to demonstrate that only a slight
amount of moisture will be able to penetrate the film and impact the internal contents which
are made up of recycled paper cellulose.
In the case of the Woolcool Fleece Liner and the Landpack Landbox Hemp Liner, the
permeable films protecting the internal materials suggest that once moisture penetrates the
packaging, then it may not be suitable for multiple uses as an insulating packaging material.
It was also observed that during one experiment involving the use of PCMs, that 3 of
the 4 packages experienced instances where the PCM had small holes and that water
melted into the package. This was the Supaso Ecoliner, EPS Inlays and the Landpack
Landbox Hemp liner. The postage box containing the EPS Inlays was soaked to the point
where it could not be re-used. The box containing the Landpack Landbox Hemp liner
remained dry, as the excessive moisture was taken up by the insulating materials. This
resulted in the box suitable for future use, however the insulating materials would not be
suitable for re-use without first drying out the contents. The box containing the Supaso
82
Ecoliner was also affected, however water had formed in a pool and there was no visible
signs of damage to the internal material of this insulation.
This is important to know in regards to the postage of temperature sensitive goods as
the build up of moisture may have a negative impact on the contents. From a re-use
perspective, the Supaso Ecoliner would be able to experience multiple uses simply by wiping
away the moisture, as with the EPS Inlays, however this moisture build up may impact the
products which are been shipped. The box containing each insulation will have to be
discarded. As for the Landpack Landbox Hemp, and what is hypothesized about the
Woolcool Fleece Liner, the fact that the films are permeable may be advantages in that they
will draw the moisture away from the carried goods and protect them from water damage.
However in regards to usability, this will likely result in the insulating materials having to be
discarded.
83
In order to understand how insulated packages perform in the real world, a delivery
test was undertaken. Identical shipping boxes were purchased from Österreichische Post AG
where each insulating material was inserted, and in the case of EPS Inlays, was cut to size.
Into each box 2 dummy packages were placed between a PCM, one on both the top and
bottom, and the contents securely held in place with 4 rubber bands. Tive tag temperature
monitors were place on the external wall of each box to record the change in temperature
experienced throughout the packages processing in the postal service. Another temperature
monitor was placed between the 2 dummy packages to determine the temperature change of
the items and another temperature monitor was placed on the internal side of the insulating
materials to determine the temperature changes occurring on the inside of the packages.
Packages were placed into the postal system in Vienna where total packaging weight
and costs were recorded. The packages were sent with a normal delivery priority and took
over 38 hours to arrive. Temperature monitors had gathered data at 5 minute intervals.
Of all the packages delivered, the Supaso Ecoliner was the only material to the
package temperature under 8°C which is the temperature most food and pharmacutical
products must be delivered at. This is in stark contrast to information on the website of
Landpack and Woolcool which claim to keep packages cool for 48 to 72 hours. This occurred
at around the 28 hour mark. This could however be due to the fact that only 2 PCMs were
included in each of the packages, if more were to be included, this may have influenced this
result.
Surprisingly, the internal temperature of the EPS Inlay package remained cooler than
the Landpack Landbox hemp material for the first 24 hours, whereas it outperformed the
Woolcool Fleece Liner all together.
The Supaso Ecoliner was the best performing material in that is kept the dummy
packages at a relatively stable temperature, well below the 8°C limit and the internal
packaging temperature was also the coldest from each of the insulating materials. However,
it must be noted that this was also the heaviest package and one of the most expensive to
send through the postal system.
While each material was able to keep contents under 8°C for at least 24 hours, the
EPS Inlays experienced both the highest and lowest temperature experienced by the dummy
packages. The Woolcool Fleece Liner demonstrated the highest interior package
temperature and the Supaso Ecoliner experienced the coldest interior temperature while its
highest package temperature was still far lower than the lowest internal temperatures
recorded from the other materials.
The Supaso Ecoliner outperformed each of the other materials in regards to keeping
contents cool, as well as for the longest period of time, with little change in temperature
84
despite the high external temperatures experienced throughout the parcel processing.
However this performance comes at a cost. The Supaso Ecoliner is also the most heaviest
material and cost the most to send.
85
8.0. Conclusion
As negative consumer sentiment towards single use plastic materials is growing

alongside expanding global commerce, consumption and reliance on these materials, there
has become a new set of challenges and opportunities associated with the distribution of
temperature sensitive goods which require unbroken cold chain logistics. Coupled with
growing concerns regarding the production, consumption and disposal of single use plastics
is a heightened awareness to end of life options for packaging materials.
To address these social and environmental issues whilst also providing viable
packaging alternatives that fulfill the functions of thermal insulating packaging , solutions that
provide the necessary light-weight, low-cost , biodegradable and sustainable alternatives to
conventional EPS packaging, this simple change of material selection may be able to provide
the least disruptive, yet radical change to plastic consumption while improving the
sustainability of temperature sensitive goods distribution.
Novel thermal insulation materials derived from hemp, wool and recycled paper have
the potential to provide an effective solution to conventional material for shipping temperature
sensitive food and pharmaceutical goods. Novel materials were subject to a number of tests
to assess and compare their thermal performance characteristics against that of EPS
packaging panels.
To further reduce the environmental impact of single use packaging materials, it was
important to select novel materials which made use of sustainable and renewable materials
with improved EOL options. Reporting on the performance of these novel packaging
materials will allow for practitioners in the field of cold chain transportation and logistics to
make better decisions regarding the choice of materials that provide adequate insulating
qualities to the goods been transported.
It can be reported that Supaso Ecoliner was the best overall performing insulation
material when it comes to thermal insulation properties. While cost, weight, overall
environmental impact, disposal techniques and degradation rates, customer acceptance and
other considering factors need to be considered when it comes to selecting the appropriate
packaging material, these factors were beyond the scope of this thesis.
However, additional research is needed to better understand the full life cycle impact
of novel materials and how they can be safely and effectively managed at the EOL, all which
impact the overall sustainability of the product.
This thesis demonstrates that novel materials are capable of performing as good, if
not better than, EPS and highlights their potential for use in the delivery of temperature
sensitive products. Additional testing of mechanical properties may help identify other
markets for which wool, hemp and recycled paper insulation material may be beneficial.
86
Of the experiments performed, the insulating material with the best overall
performance was the Supaso Ecoliner. The recycled paper from which the packaging is
made from has a lower density and yet relatively similar thermal conductivity compared to the
remaining materials. This means that more material can be packed closer together, reducing
air between the surface of its fibers and therefore reducing the ability for heat to travel
through the material. However, this does come at a cost. The higher density material was
among the most expensive to send through the postal system. However, if sending
temperature sensitive goods, it may be worth to incur the extra financial cost to ensure that
the goods arrive to the end consumer within the specified temperature range.
These properties were integral to the Supaso Ecoliner material in maintaining the
lowest internal package temperature with the aid of PCMs, and was also able to maintain
product temperature below 0°C for the longest period of time. It was also the reason for this
material experiencing the lowest average melt rate and lowest R-values among the insulating
materials.
In order to continue assessing the performance of novel materials as insulation
packages, additional test to understand the mechanical properties could be of benefit to
determine actual packaging needs and reduce the impact of over packaging. In depth LCAs
of ech material, including data on actual disposal rates and methods of alternative materials
will also go a lone way to fully understanding the environmental impact of using these against
conventional materials. Additionally, undertaking humidity tests would be beneficial in order
to assess the suitability of these materials been sent loner distances and how the build up of
moisture can impact the internal contents of the package.
Not only is this research paper of interest to those in the packaging and logistics
industry, there may be value draw from this research in the construction industry in relation to
insulating materials.
87
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10.0. Appendix 1 - Detailed Results
10.6.1. R - Value of Insulating Packaging Materials
Internal Dimensions (m)

Material L W H Surface Area (m2)
EPS Inlays 0.28 0.25 0.21 0.36
Landpack Landbox Hemp 0.28 0.25 0.23 0.38
Woolcool Fleece Liner 0.24 0.24 0.24 0.35
Supaso Ecoliner 0.25 0.25 0.20 0.39
Table: Surface area of insulating materials
Date 23/07/2023 24/07/2023 Freezer Temp. (°C) -24

Time 22:45 22:45 Water amount (L) 1
Room Temp. (°C) 22.6 22.4
Humidity (%) 60 67
Ice weight Ice weight Weight Water Melt rate
Material R-Value
Hour 0 (kg) Hour 24 (kg) Collected (kg) (kg/hr)
EPS 0.935 0.182 0.753 0.031 0.77
Box 2 0.973 0.282 0.691 0.029 0.89
Box 3 0.963 0.394 0.569 0.024 0.97
Supaso 0.969 0.541 0.428 0.018 1.08
Table: System R-value Results Test 1.
Date 24/07/2023 25/07/2023 Freezer Temp. (°C) -22

Time 23:00 23:00 Water amount (L) 1
Room Temp. (°C) 22.5 21.7
Humidity (%) 67 71
Ice weight Ice weight Weight Water Melt rate
Material R-Value
Hour 0 (kg) Hour 24 (kg) Collected (kg) (kg/hr)
EPS 0.923 0.176 0.747 0.031 0.78
Box 2 0.936 0.306 0.630 0.026 0.97
Box 3 0.947 0.407 0.54 0.023 1.02
Supaso 0.951 0.545 0.406 0.017 1.14
Table: System R-value Results Test 2.
95
10.6.3. Latent Heat and Heat Absorption of Phase Change Materials
Date Time Temp (°C) Minutes

3/08/2023 10:46:45 19.33 0
3/08/2023 10:51:46 19.33 5
3/08/2023 10:56:48 17.07 10
3/08/2023 11:01:49 12.82 15
3/08/2023 11:06:51 11.56 20
3/08/2023 11:11:52 10.31 25
3/08/2023 11:16:54 10.31 30
3/08/2023 11:21:56 9.56 35
3/08/2023 11:26:57 9.03 40
3/08/2023 11:31:59 8.78 45
3/08/2023 11:37:00 8.53 50
3/08/2023 11:42:02 8.53 55
3/08/2023 11:47:03 8.53 60
3/08/2023 11:52:05 8.25 65
3/08/2023 11:57:07 8.25 70
3/08/2023 12:02:08 8.25 75
3/08/2023 12:07:10 8.53 80
3/08/2023 12:12:11 8.53 85
3/08/2023 12:17:13 8.78 90
3/08/2023 12:22:15 9.03 95
3/08/2023 12:27:16 9.03 100
Table: Data collected from Latent Heat and Heat Absorption of PCM Test 1.
Figure: Temperature Profile of Latent Heat and Heat Absorption of PCM Test 1.
96
Date Time Temp Minutes
3/08/2023 10:45:39 19.58 0
3/08/2023 10:50:42 19.33 5
3/08/2023 10:55:44 19.33 10
3/08/2023 11:00:46 14.32 15
3/08/2023 11:05:48 12.57 20
3/08/2023 11:10:50 11.56 25
3/08/2023 11:15:52 10.81 30
3/08/2023 11:20:54 10.06 35
3/08/2023 11:25:57 10.06 40
3/08/2023 11:30:59 10.06 45
3/08/2023 11:36:01 9.56 50
3/08/2023 11:41:03 9.03 55
3/08/2023 11:46:05 8.78 60
3/08/2023 11:51:07 8.53 65
3/08/2023 11:56:09 8.53 70
3/08/2023 12:01:12 8.53 75
3/08/2023 12:06:14 8.53 80
3/08/2023 12:11:16 8.53 85
3/08/2023 12:16:18 8.53 90
3/08/2023 12:21:20 8.53 95
3/08/2023 12:26:22 8.78 100
Table: Data collected from Latent Heat and Heat Absorption of PCM Test 2.
Figure: Temperature Profile of Latent Heat and Heat Absorption of PCM Test 2.
97

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Comparison of novel materials for thermal packaging

solutions in cold chain logistics.

For the degree of

Master of Science in Engineering (MSc)

by University of Applied Sciences - FH Campus Wien

II. Key Words

2.0. Aim and Research Question 11

3.0. Literature Review 12

10.0. Appendix 1 - Detailed Results 95

Figure 1: Optimal Packaging 15

Figure 30: 24 hour Temperature Monitoring with PCMs - Woolcool

Table 1: Share of Most Important Types of Plastics in Production and Waste 23

Cold chain logistics is the unbroken temperature-controlled supply chain of sensitive

Packaging materials, particularly food packaging, is becoming an interesting yet

 Different types of materials;

Although low cost, customer appeal, mechanical strength, application, environmental

3.1. Part 1 - A Brief History of Temperature Controlled Packaging

3.2. Part 2 - Logistics of Temperature Sensitive Products

3.2.1. Importance of Packaging in Cold Chain Logistics

Figure 1: Optimal Packaging (Source: Pereira et al., 2015).

3.2.2. Food Products

Although temperature sensitive products can be delivered anywhere from -10°C to

3.2.4. Food Safety Issues

Food exposed to unacceptable temperature ranges during dispatch and logistics

3.2.6. Non - Food Waste

3.2.7. Non - Food Safety Issues

3.2.8. Phase Change Materials

3.3. Part 3 - Conventional Cold Chain Packaging Material

3.3.1. Expanded Polystyrene Inlays

3.3.2. Environmental Considerations of Conventional Packaging Material

A significant portion of plastic consumption has come as a result of packaging use,

3.3.3 Advantages and Disadvantages of Conventional Packaging Material

3.4.1. Novel Packaging Materials

Consumers are becoming increasingly aware of the environmental and social

3.4.2. Environmental Considerations of Novel Packaging Materials

Circularity of the chosen packaging solutions is achieved by the selection of recycled

4.1 EPS Inlays

Figure 6: EPS Inlays Inside Postal Box.

EPS is derived from the polymerization of phenylethane (styrene monomer), and is

Figure 7: EPS Inlay.

Supaso GmbH is a sustainable packaging company based in Austria developing a

Information regarding the Supaso Ecoliner are as follows:

Figure 10: Internal Contents of Supaso Ecoliner.

Information regarding Landpack Landbox Hemp are as follows:

Figure 13: Internal Contents of Landpack Landbox Hemp Liner.

Woolcool claims to be a sustainable packaging solution that uses renewable sheep’s

Information regarding Woolcool Fleece Liner are as follows:

Figure 16: Internal Contents of Woolcool Fleece Liner.

Figure 17: Österreich Post AG Paket Box Large.

Properties of packaging materials

Figure 18: Tive Tag Temperature Logger (Front and Rear).

4.7. Cold Packs

4.8. Kraft Paper Gel Packs

Coolways is a Netherlands based company which specialises in developing chilled

Figure 20: Coolways Kraft Paper Gel pack.

5.1. R - Value of Insulating Packaging Materials

Scope: The R-value is the ability of a material to resist heat flowing an

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