Replacing Polystyrene with a Cost-Effective, Space-Saving Cold Chain Solution

CLIENT BACKGROUND

Aquafresh delivers fresh seafood across New Zealand, supplying nearby restaurants and retailers as well as locations nationwide. Despite many deliveries only taking 1–2 hours, they were using traditional polystyrene packaging for all shipments - resulting in high costs, inefficient storage, and unnecessary waste.

The company needed a better packaging solution to reduce costs, save space, and support their growth - without compromising product quality.

CLIENT REQUIREMENTS

Aquafresh’s operational constraints shaped the project requirements:

• Compact Footprint – Minimal packing space and limited storage capacity meant packaging had to be space-efficient.
• Production Line Friendly – Needed to streamline packing on an already tight production line.
• Leakproof and Durable – Performance had to hold up for at least 24 hours, with no risk of leaks.
• Polystyrene Replacement – Packaging had to be more sustainable and affordable than traditional poly.

UNIQUE PROJECT CHALLENGES

• ‍Site Constraints – Aquafresh’s production volume had outgrown their facility, but they weren’t ready to move. Every packaging change had to help maximise space and through put within their existing site footprint.

THERMOGARD SOLUTION

Thermogard delivered a lightweight, recyclable cold chain packaging system built for efficiency and performance:

• ‍EnviroFoil Insulation – Chosen for its reliable thermal performance, low cost, and ease of handling in a fast-paced production environment.‍
• Recyclable Cardboard Outer Carton – Replaced bulky poly with a space-saving, kerbside recyclable carton.‍
• Segmented Gel Ice Packs (6 cell, 400g) – Easy to position and effective in maintaining cold chain integrity.‍
• Fully Recyclable Materials – Both the insulation and the outer box supported Aquafresh’s sustainability goals and disposal simplicity.

END RESULT‍

The new solution delivered tangible operational and environmental benefits:

• ‍No Drop in Delivery Performance – Maintained product integrity across all routes, with no increase in failed deliveries.‍
• Lower Packaging Costs – Reduced reliance on costly polystyrene while improving supply chain efficiency.‍
• Happier Factory Team – Production staff appreciated the new system’s simplicity and space efficiency.‍
• Improved Storage & Workflow– Freed up valuable space in both the packing and storage areas.

Aquafresh successfully moved to a leaner, more sustainable packaging model - supporting both their growth and their commitment to quality.