Delivering a Recyclable, High-Performance Paper-Based Cold Chain Pouch for Global Fulfilment

CLIENT BACKGROUND

A global leader in the meal kit industry, this brand delivers chef-designed recipes and fresh ingredients directly to consumers across multiple continents. With operations spanning Europe, North America, and Australia, the company is known for its commitment to culinary innovation, sustainability, and supply chain efficiency. As their business scaled, so did their need for packaging solutions that could align with both their environmental goals and complex global logistics.

CLIENT REQUIREMENTS

To support a global, high-speed operation, the client needed a next-generation cold chain pouch that could:

• Replace Plastic with Paper – Match the performance of plastic-based pouches using a recyclable paper solution.
• Ensure Structural Integrity – Withstand moisture exposure and rough handling without compromising contents.
• Improve Thermal Performance – Reduce temperature excursions to improve product 'time-in-temp' during transit.
• Maintain Unit Cost Targets – Deliver performance, sustainability, and speed within established per-unit budget constraints.

UNIQUE PROJECT CHALLENGES

The client required a recyclable packaging alternative that didn’t sacrifice cost, packing speed or product protection was made further complexity by needing full supply chain management for sites globally, working with global head office, and regional buying teams.

• Maintain Picking Line Speed – Preserve high throughput during automated and manual packing processes.
• Enable Regional Fulfilment at a Global Scale – Manage in-region supply chain to facilities worldwide on a regular cadence, despite tight storage constraints at each site.

THERMOGARD SOLUTION

Thermogard delivered a robust, paper-based cold chain pouch engineered for global scale and thermal performance:

• Specialty Barrier-Coated Paper Pouch – Featuring a recyclable barrier coating that reduced thermal transfer and minimized moisture impact on structural integrity.
• Fold+Seal Top Design – Enabled airtight sealing, simplifying packing while improving insulation and minimizing heat ingress.
• Virgin High GSM Paper Substrate – Provided enhanced durability and rigidity for high-speed line compatibility.
• Regional Fulfillment Strategy – Deployed across global fulfillment sites with consistent cadence, supporting space- and logistics-constrained environments.

END RESULT

The client successfully transitioned to a recyclable, high-performance cold chain pouch while optimizing fulfillment operations:

• Plastic Eliminated – Transitioned from plastic-based pouches to a fully recyclable paper solution.
• Line Speed Maintained – Achieved seamless integration into existing packing operations.
• Thermal and Structural Gains – Improved cold chain performance and moisture resistance.
• Budget Delivered – Through smart engineering and material optimization, the solution was delivered within the client’s target per-unit cost.
• Global Deployment Enabled – Now maintain 98% global DIFOT, while managing international shipping schedules and regional distribution.

With Thermogard’s innovation, the client now delivers freshness, sustainability, and cost-efficiency at global scale - keeping meal kits protected and customers delighted, every step of the way.

‍