Boosting Cold Chain Efficiency with a Cost-Effective, Locally-Supplied Packaging Solution

CLIENT BACKGROUND

ButcherCrowd is a family-owned online meat delivery company with a growing reputation for premium, sustainably sourced meats and wild-caught seafood. Operating out of Sydney with a head office in Queensland, they offer flexible subscriptions delivering high-quality protein to customers across Australia.

CLIENT REQUIREMENTS

To maintain their premium brand promise, ButcherCrowd needed packaging that:

• Protect Frozen and Chilled Goods – Keep products in optimal condition through up to 48 hours of refrigerated transport, plus 4–6 hours on the doorstep.
• Improve Efficiency During Packing – Packaging had to be fast and easy to handle at a third-party logistics (3PL) facility.
• Support Nationwide Distribution – Reliable performance was critical for expanding their delivery footprint.
• Reduce Dependency on Imports – Existing packaging relied on imported materials, introducing supply chain risk.

UNIQUE PROJECT CHALLENGES

Third-Party Fulfilment – Shipments were packed and dispatched from a 3PL location, meaning any packaging solution had to be simple to use, efficient to pack, and perform consistently without direct oversight from ButcherCrowd’s team.

THERMOGARD SOLUTION

Thermogard replaced ButcherCrowd’s previous wool liners and gel bricks with a high-performance, more efficient solution:

• Gusseted EnviroFoil Pouch with Adhesive Closure – Provided superior insulation, easier handling, and a snug fit for various box sizes.
• Segmented Gel Ice Packs – Enhanced thermal control and distribution of cooling across the box interior.
• Simplified Packout Process – The new configuration reduced complexity and packing time at the 3PL site.

This switch not only improved thermal performance but also reduced packaging bulk and cost.

END RESULT

ButcherCrowd gained a reliable, scalable packaging system that elevated operational efficiency and cold chain performance:

• Improved Packaging Efficiency – Gusseted pouches streamlined packing and increased throughput at the 3PL facility.
• Lower Packaging Costs – The switch from imported wool and gel bricks to local solutions cut costs without sacrificing performance.
• Stronger Cold Chain Performance – Allowed wider distribution with greater temperature consistency during delivery.
• More Reliable Supply Chain – Sourced from a steady local manufacturer, reducing lead times and dependency on overseas materials.

The result is a packaging system that supports ButcherCrowd’s brand growth and sustainability goals - with less complexity and more consistency.

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