What Are Thermopore Boxes?
Thermopore boxes — also called EPS (expanded polystyrene) boxes or styrofoam boxes — are lightweight insulated containers. They look like simple white boxes, but their thick foam walls trap cold air inside and keep hot air outside. Learn more about expanded polystyrene on Wikipedia.
For ice cream sellers, dairy brands, and frozen food businesses in Pakistan, thermopore boxes are the backbone of safe delivery. Without them, ice cream melts before it reaches the customer — especially in summer.
Why Thermopore Boxes Are Essential for Dairy
Ice cream must stay below -18°C. Milk, yogurt, and cheese need 2–4°C. In a Pakistani summer, an ordinary cardboard box or plastic bag cannot hold these temperatures for even one hour.
A good thermopore box:
- Keeps cold in, heat out – thick insulation slows temperature change dramatically
- Is lightweight – adds almost no weight to your delivery cost
- Protects from shocks – cushions products on bumpy roads
- Works with dry ice and gel packs – designed to pair with cooling materials
- Is affordable – much cheaper than refrigerated vehicles for small shipments
Choosing the Right Size
Thermopore boxes come in many sizes. Here is how to choose:
- Small (2–5 litres) – home delivery of 1–2 ice cream tubs or small dairy orders
- Medium (10–20 litres) – shop restocking, catering orders, online grocery
- Large (30–50+ litres) – bulk transport, intercity shipments, distributor supply
Golden rule: Choose a box that fits your products snugly. Empty air space inside the box warms up faster. Fill gaps with extra gel packs or packing material.
How to Pack Ice Cream in a Thermopore Box – Step by Step
Step 1 – Pre-chill the Box
If possible, keep the empty box in a cool place before packing. A warm box melts your cooling materials faster.
Step 2 – Add a Base Layer
Place dry ice blocks or frozen gel packs at the bottom of the box.
Step 3 – Load Products Quickly
Put pre-frozen ice cream or dairy products in the box as fast as possible. Do not leave the box open in the heat.
Step 4 – Fill the Gaps
Add gel packs around and on top of the products. Fill any empty space — air gaps are the enemy.
Step 5 – Seal Tightly
Close the lid firmly. For long journeys, seal the edges with tape to stop cold air escaping.
Step 6 – Label and Dispatch
Mark the box “Keep Frozen” and dispatch immediately. Night or early morning dispatch is best in summer.
Dry Ice vs Gel Packs Inside Thermopore Boxes
- Ice cream, intercity (6+ hours) → Dry ice blocks
- Ice cream, city delivery (1–3 hours) → Gel packs
- Milk/yogurt/cheese → Gel packs (dry ice is too cold)
- Mixed frozen + chilled → Gel packs with separation
Important: Dry ice is so cold (-78.5°C) that it can freeze milk and yogurt solid. For chilled (not frozen) dairy, gel packs are the safer choice.
How Long Does Ice Cream Last in a Thermopore Box?
With proper packing:
- Gel packs only: 3–6 hours in summer
- Dry ice blocks: 12–24 hours depending on quantity and box thickness
- Combination: best results for long routes
Thicker box walls always perform better. A cheap thin box can cut your cold time in half.
Common Mistakes to Avoid
- Using a box that is too big – extra air space melts everything faster
- Opening the box during transit – every opening lets cold out
- Weak or half-frozen gel packs – freeze gel packs for a full 24 hours before use
- Dispatching at noon – the hottest part of the day is the worst time
- Reusing damaged boxes – cracked boxes leak cold air; replace them
Thermopore Boxes for Online Sellers
If you sell ice cream, kulfi, frozen desserts, or dairy online, your packing IS your brand. Customers judge you by what arrives at their door. A melted tub means a refund, a bad review, and a lost customer. Investing in good boxes and gel packs pays for itself in repeat orders.
Where to Buy Thermopore Boxes in Pakistan
We supply durable insulated thermopore boxes in multiple sizes, along with dry ice and reusable gel packs — everything you need for dairy and ice cream transport in one place. Delivery available across Punjab, Sindh, KPK, and Balochistan. See our dry ice supplier Pakistan guide for bulk dry ice orders.
Call or WhatsApp 0321-2627965 to order thermopore boxes, dry ice, and gel packs for your dairy business.
Frequently Asked Questions
Are thermopore boxes reusable? Yes, if they are not cracked or damaged. Wipe them clean and reuse. Replace boxes with broken lids or cracks.
Can I use thermopore boxes for medicines? Yes, they are widely used for vaccine and medicine transport with gel packs.
What is the price of thermopore boxes in Pakistan? Price depends on size and wall thickness. Call 0321-2627965 with your required size for a quote.
Are thermopore boxes waterproof? They resist moisture well, but they are not fully waterproof. Keep them out of heavy rain during transport.
