Insulated Shipping Box Size Chart: Foam Cooler Kits, Inside Dimensions and Cold Packs

Updated September 2, 202641 insulated shippers33 cold packs

Insulated shipping kits are sized by the foam cooler's inside dimensions, and the space has to hold product and cold packs together. The chart lists every stocked kit by inside size, volume in cubic inches and quarts, wall thickness and format, the gel packs that fit, and the starting rules for how many packs a refrigerated, frozen or chilled shipment needs.

Stocked insulated shippers by inside size

An insulated shipping kit is a molded expanded polystyrene (EPS) cooler inside a corrugated box sized to it. The foam does the insulating; the box carries the label, survives the conveyor and lets the kit stack. Kits are named by the foam's inside dimensions, which is the space left for product and cold packs together, so pick a size by the packed volume, not the product alone.

Live catalog on September 2, 2026. Sizes are the foam cooler's inside dimensions as listed; the corrugated outer adds the wall thickness plus about 1/4 in per side. Volume is before cold packs.
Insulated shipper Inside size (L x W x H) Inside volume Quarts Foam wall Format Per case Case price Each
6x4.5x3 Insulated Shipping Kit EPS Foam Corrugated Box 24/Case 6 x 4.5 x 3 in 81 cu in 1.4 qt see product kit (foam cooler + corrugated outer) 24 $147.16 6.13
6x5x4.5 EPS Foam Insulated Shipping Kits 8/Case 6 x 5 x 4.5 in 135 cu in 2.3 qt see product kit (foam cooler + corrugated outer) 8 $79.91 9.99
8x6x4.25 EPS Foam Insulated Shipping Kits 12/Case 8 x 6 x 4.25 in 204 cu in 3.5 qt see product kit (foam cooler + corrugated outer) 12 $107.12 8.93
6x6x6 Insulated Box Liners 25/Case 6 x 6 x 6 in 216 cu in 3.7 qt see product see product 25 $230.10 9.20
8x6x7 EPS Foam Insulated Shipping Kits 8/Case 8 x 6 x 7 in 336 cu in 5.8 qt see product kit (foam cooler + corrugated outer) 8 $98.34 12.29
8x6x9 Insulated Foam Shipping Container 8/Case 8 x 6 x 9 in 432 cu in 7.5 qt see product foam container only 8 $80.00 10.00
8x6x9 EPS Foam Insulated Shipping Kits 8/Case 8 x 6 x 9 in 432 cu in 7.5 qt see product kit (foam cooler + corrugated outer) 8 $99.84 12.48
8x8x8 FDA Food Safe Aluminum Foil Insulated Box Liners 25/Case 8 x 8 x 8 in 512 cu in 8.9 qt see product see product 25 $167.70 6.71
11x8x6 Insulated Box Liners Aluminum Foil Bubble 25/Case 11 x 8 x 6 in 528 cu in 9.1 qt see product see product 25 $100.75 4.03
8x6x12 EPS Foam Insulated Shipping Kits 1/Case 8 x 6 x 12 in 576 cu in 10.0 qt see product kit (foam cooler + corrugated outer) 1 $14.78 14.78
12x10x5 EPS Foam Insulated Shipping Kits 4/Case 12 x 10 x 5 in 600 cu in 10.4 qt see product kit (foam cooler + corrugated outer) 4 $74.81 18.70
9.5x9.5x7 EPS Foam Insulated Shipping Kits 1/Case 9.5 x 9.5 x 7 in 632 cu in 10.9 qt see product kit (foam cooler + corrugated outer) 1 $14.37 14.37
10.5x8.25x9.25 EPS Foam Insulated Shipping Kits 2/Case 10.5 x 8.25 x 9.25 in 801 cu in 13.9 qt see product kit (foam cooler + corrugated outer) 2 $45.40 22.70
12x10x7 EPS Foam Insulated Shipping Kits 1/Case 12 x 10 x 7 in 840 cu in 14.5 qt see product kit (foam cooler + corrugated outer) 1 $24.43 24.43
19.5x11.5x4.125 Insulated Shipping Kit 19.5 x 11.5 x 4.125 in 925 cu in 16.0 qt see product kit (foam cooler + corrugated outer) 1 $24.44 24.44
10x10x10 Aluminum Foil Bubble Lined Insulated Box Liners 25/Case 10 x 10 x 10 in 1,000 cu in 17.3 qt see product see product 25 $135.42 5.42
12x10x9 Aluminum Foil Bubble Lined Insulated Box Liners 25/Case 12 x 10 x 9 in 1,080 cu in 18.7 qt see product see product 25 $135.20 5.41
12x10x9 Insulated Foam Container 1/Case 12 x 10 x 9 in 1,080 cu in 18.7 qt see product foam container only 1 $19.76 19.76
12x10x9 EPS Foam Insulated Shipping Kits 1/Case 12 x 10 x 9 in 1,080 cu in 18.7 qt see product kit (foam cooler + corrugated outer) 1 $27.59 27.59
14x10x10 Insulated Box Liners 25/Case 14 x 10 x 10 in 1,400 cu in 24.2 qt see product see product 25 $171.70 6.87
17x10x8.25 EPS Foam Insulated Shipping Kits 1/Case 17 x 10 x 8.25 in 1,402 cu in 24.3 qt see product kit (foam cooler + corrugated outer) 1 $32.17 32.17
12x12x11.5 EPS Foam Insulated Shipping Kits 1/Case 12 x 12 x 11.5 in 1,656 cu in 28.7 qt see product kit (foam cooler + corrugated outer) 1 $39.98 39.98
12x12x12 Insulated Box Liners Aluminum Foil Bubble 25/Case 12 x 12 x 12 in 1,728 cu in 29.9 qt see product see product 25 $166.83 6.67
17x10x10.5 EPS Foam Insulated Shipping Kits 1/Case 17 x 10 x 10.5 in 1,785 cu in 30.9 qt see product kit (foam cooler + corrugated outer) 1 $34.48 34.48
13.75x11.75x11.875 EPS Foam Insulated Shipping Kits 1/Case 13.75 x 11.75 x 11.875 in 1,919 cu in 33.2 qt see product kit (foam cooler + corrugated outer) 1 $35.28 35.28
13x13x12.5 EPS Foam Insulated Shipping Kits 1/Case 13 x 13 x 12.5 in 2,112 cu in 36.6 qt see product kit (foam cooler + corrugated outer) 1 $37.92 37.92
18x12x12 Insulated Box Liners 25/Case 18 x 12 x 12 in 2,592 cu in 44.9 qt see product see product 25 $185.54 7.42
17x17x9 Insulated Shipping Kit EPS Foam Corrugated Box Case 17 x 17 x 9 in 2,601 cu in 45.0 qt see product kit (foam cooler + corrugated outer) 1 $49.98 49.98
14x14x14 Aluminum Foil Bubble Lined Insulated Box Liners 15/Case 14 x 14 x 14 in 2,744 cu in 47.5 qt see product see product 15 $164.32 10.95
19x12x12.5 EPS Foam Insulated Shipping Kits 1/Case 19 x 12 x 12.5 in 2,850 cu in 49.4 qt see product kit (foam cooler + corrugated outer) 1 $39.00 39.00
16x16x16 Insulated Box Liners 15/Case 16 x 16 x 16 in 4,096 cu in 70.9 qt see product see product 15 $193.44 12.90
16.75x16.75x15 Insulated Shipping Kit 16.75 x 16.75 x 15 in 4,208 cu in 72.9 qt see product kit (foam cooler + corrugated outer) 1 $57.46 57.46
18x14x19 EPS Foam Insulated Shipping Kits 1/Case 18 x 14 x 19 in 4,788 cu in 82.9 qt see product kit (foam cooler + corrugated outer) 1 $43.65 43.65
25x16.5x12 Insulated Shipping Kits 25 x 16.5 x 12 in 4,950 cu in 85.7 qt see product kit (foam cooler + corrugated outer) 1 $63.79 63.79
21.25x15.5x15.5 EPS Foam Insulated Shipping Kits 1/Case 21.25 x 15.5 x 15.5 in 5,105 cu in 88.4 qt see product kit (foam cooler + corrugated outer) 1 $61.33 61.33
26x19.75x10.5 EPS Foam Insulated Shipping Box 26 x 19.75 x 10.5 in 5,392 cu in 93.4 qt see product see product 1 $81.03 81.03
18x18x18 Aluminum Foil Bubble Lined Insulated Box Liners 10/Case 18 x 18 x 18 in 5,832 cu in 101.0 qt see product see product 10 $173.12 17.31
30.25x14.5x16 Insulated Shipping Kits 30.25 x 14.5 x 16 in 7,018 cu in 121.5 qt see product kit (foam cooler + corrugated outer) 1 $71.93 71.93
23x14x23 Insulated Shipping Kits 23 x 14 x 23 in 7,406 cu in 128.2 qt see product kit (foam cooler + corrugated outer) 1 $158.57 158.57
24x18x18 Insulated Box Liners Aluminum Foil 10/Case 24 x 18 x 18 in 7,776 cu in 134.6 qt see product see product 10 $185.12 18.51
20x20x20 Aluminum Foil Insulated Box Liners 10/Case 20 x 20 x 20 in 8,000 cu in 138.5 qt see product see product 10 $198.64 19.86

Wall thickness sets hold time more than box size does: a 1.5 in wall holds temperature roughly 40 to 60 percent longer than a 3/4 in wall in the same ambient conditions. Two small shippers lose heat faster than one large one because surface area per quart is higher, so consolidate where the carrier weight allows. The carrier size and weight limits page covers the parcel ceilings and the DIM weight chart the billing on bulky, light foam kits.

Cold packs that fit

Cold packs ship unfrozen; freeze flat for 24 hours before use. A 10 x 6 x 1.5 in gel pack holds roughly 16 oz; check the product page for the fill weight.
Cold pack Size Fill Per case Case price Each
6 oz Moisture Safe Cold Packs 96-Pack see product see product 96 $72.50 0.76
5x2.75x0.75 Gel Refrigerant Cold Packs 96/Case 5 x 2.75 x 0.75 in gel 96 $30.90 0.32
4.5x2x1.5 Foam Refrigerant Cold Bricks 48/Case 4.5 x 2 x 1.5 in see product 48 $67.04 1.40
4.5x4x0.75 Foam Refrigerant Cold Bricks 42/Case 4.5 x 4 x 0.75 in see product 42 $61.84 1.47
5.5x4x0.75 Gel Refrigerant Cold Packs 96/Case 5.5 x 4 x 0.75 in gel 96 $43.16 0.45
5.5x4x0.75 Gel Refrigerant Cold Packs 48/Case 5.5 x 4 x 0.75 in gel 48 $25.32 0.53
6.5x4x0.75 Use Gel Cold Packs FDA GRAS 1 Each 6.5 x 4 x 0.75 in FDA GRAS gel 1 $33.15 33.15
4.5x4x1.5 Gel Refrigerant Cold Packs 12/Case 4.5 x 4 x 1.5 in gel 12 $33.05 2.75
6x5.75x1 Gel Refrigerant Cold Packs 24/Case 6 x 5.75 x 1 in gel 24 $22.04 0.92
6x6x1 Gel Refrigerant Cold Packs 48/Case 6 x 6 x 1 in gel 48 $34.57 0.72
6x6x1 Moisture Safe Tech Pack Insulated Shipper 48/Case 6 x 6 x 1 in see product 48 $54.27 1.13
6.25x6x1 Use Gel Cold Pack FDA GRAS 1 Each 6.25 x 6 x 1 in FDA GRAS gel 1 $23.75 23.75
6.25x6x1 Gel Refrigerant Cold Packs 36/Case 6.25 x 6 x 1 in gel 36 $47.32 1.31
6.25x6x1 Gel Refrigerant Cold Packs 18/Case 6.25 x 6 x 1 in gel 18 $18.55 1.03
6.25x6x1 16 oz Moisture Safe Tech Pack 36/Case 6.25 x 6 x 1 in see product 36 $33.22 0.92
7x5x1.5 Gel Refrigerant Cold Packs 12/Case 7 x 5 x 1.5 in gel 12 $29.08 2.42
9x4x1.5 Gel Refrigerant Cold Packs 6-Pack 9 x 4 x 1.5 in gel 6 $28.73 4.79
8x6x1.25 Gel Refrigerant Cold Packs 24/Case 8 x 6 x 1.25 in gel 24 $33.32 1.39
8x6x1.25 Economy Gel Cold Pack FDA GRAS 1 Each 8 x 6 x 1.25 in FDA GRAS gel 1 $26.52 26.52
8x6x1.25 Gel Refrigerant Cold Packs 12/Case 8 x 6 x 1.25 in gel 12 $17.50 1.46
8x6x1.25 24 oz Moisture Safe Tech Pack Pouches 24/Case 8 x 6 x 1.25 in see product 24 $27.43 1.14
6x4x3 Gel Refrigerant Cold Packs 72/Case 6 x 4 x 3 in gel 72 $45.59 0.63
6x4x3 Gel Refrigerant Cold Packs 36/Case 6 x 4 x 3 in gel 36 $23.20 0.64
6 x 4 x 3/4 in Moisture Safe Tech Pack Ice Brick 72/Case 6 x 4 x 3 in see product 72 $66.11 0.92
10x6x1.5 Economy Cold Pack FDA GRAS Gel 1 Each 10 x 6 x 1.5 in FDA GRAS gel 1 $22.10 22.10
10x6x1.5 Gel Refrigerant Cold Packs 9/Case 10 x 6 x 1.5 in gel 9 $15.47 1.72
10x6x1.5 Gel Refrigerant Cold Packs 18/Case 10 x 6 x 1.5 in gel 18 $27.66 1.54
8x8x1.5 Gel Refrigerant Cold Packs 9/Case 8 x 8 x 1.5 in gel 9 $15.47 1.72
11.25x9.25x1 Foam Refrigerant Cold Bricks 12/Case 11.25 x 9.25 x 1 in see product 12 $76.77 6.40
9x4x3 Gel Refrigerant Cold Packs 8/Case 9 x 4 x 3 in gel 8 $39.91 4.99
9x8x1.5 Gel Refrigerant Cold Packs 6/Case 9 x 8 x 1.5 in gel 6 $35.18 5.86
10.25x8x1.5 Use Economy Cold Pack FDA GRAS Gel 1 Each 10.25 x 8 x 1.5 in FDA GRAS gel 1 $19.89 19.89
10.25x8x1.5 Gel Refrigerant Cold Packs 6/Case 10.25 x 8 x 1.5 in gel 6 $13.26 2.21

How many cold packs a shipment needs

Starting points from common cold-chain practice; the right count depends on wall thickness, ambient temperature, product mass and transit hours. Run a test box with a temperature logger before shipping at volume. Dry ice is a hazardous material for air transport (UN 1845, 5.5 lb limit per package without a declaration) and must never be sealed airtight.
Shipment Target range Refrigerant Starting rule (overnight) Starting rule (2-day)
Chilled food, produce, dairy, pharma 35 to 45 F Frozen gel packs About 1 lb of gel per 1 lb of product, packs on top and sides About 1.5 to 2 lb of gel per 1 lb of product, thicker walls
Chocolate, cosmetics, wine in summer Under 70 F Refrigerated (not frozen) gel packs 1 pack per 3 to 5 lb of product 1 pack per 2 to 3 lb, 1.5 in wall
Frozen meat, seafood, ice cream 0 F or below Dry ice (gel packs cannot hold sub-zero) About 5 lb of dry ice per 10 lb of product per day 10 to 12 lb per 10 lb of product; vent the box
Live plants, insects, bait Above 40 F, below 80 F Gel packs or heat packs by season 1 pack per box, wrapped so it never touches the contents Same, plus paper insulation

Placement matters as much as count. Cold air sinks, so packs go on top of the product first, then along the sides; product goes on a layer of kraft paper or a corrugated pad so it does not sit in condensation. Fill the remaining void with crumpled paper, because air movement inside the cooler is what carries heat in. Keep frozen gel packs off direct contact with produce and chocolate (they freeze-burn) by wrapping them in a poly bag or a sheet of paper.

Packing an insulated kit

  1. Pre-chill. Freeze gel packs flat for 24 hours; chill the product to its target before packing; a warm product uses up half the refrigerant before the box leaves the dock.
  2. Line and layer. Kraft paper or a pad on the floor of the cooler, product in a sealed 2 or 4 mil poly bag, packs on top and sides.
  3. Fill the void. Paper or bubble in every gap; a half-empty cooler warms fastest.
  4. Seal the foam lid with tape unless dry ice is inside, in which case leave it unsealed so gas can vent.
  5. Close and label the outer box. Perishable and This Side Up labels on two faces; the dry ice label with net weight when used.
  6. Ship early in the week. Overnight or 2-day service Monday to Wednesday so the box is never in a hub over a weekend.

Kit vs foam-only vs insulated mailer

Foam-only containers save money when you already stock a box that fits the cooler, and they are what a reusable program returns. Insulated bubble mailers (foil-faced bubble inside a poly mailer) handle a single chilled item for a few hours at a fraction of the size and cost, but do not hold a temperature overnight. For anything over 12 hours in transit, use the kit.

Shop insulated shippersShop cold packsBulk quote

Frequently asked questions

What size insulated shipping box do I need?

Size by packed volume: product plus cold packs plus void fill. Add up the product's cubic inches, add about the same again for gel packs on an overnight refrigerated shipment, and pick the kit whose inside volume covers it with a little room for paper.

How many ice packs do I need to ship refrigerated food overnight?

As a starting point, about one pound of frozen gel pack per pound of product, placed on top and along the sides in a 1.5 in wall cooler. Test with a temperature logger and adjust for season.

Can I ship frozen food with gel packs?

Not reliably. Gel packs hold 32 to 40 F; frozen goods at 0 F need dry ice, about 5 pounds per 10 pounds of product per day of transit, in an unsealed foam cooler.

How long does a foam cooler keep things cold?

With enough refrigerant, a 1.5 in wall EPS cooler holds refrigerated temperature 48 to 72 hours; a 3/4 in wall about 24 to 36 hours. Ambient temperature and how full the box is change both figures.

Do insulated shipping kits need a special label?

Perishable and orientation labels are good practice for any cold shipment. Dry ice requires the UN 1845 dry ice label with net weight, and air shipments over 5.5 pounds need a shipper's declaration.

Related references