Hydropac has introduced EcoCool, a new paper-fibre insulated box liner designed to combine thermal insulation and cushioning protection for temperature-sensitive products during transit.
The liner has been developed as an alternative to conventional insulation materials, including polystyrene, loose paper fill, cotton, jute and wool. It is available for use in 10″, 12″ and 14″ cubed box systems.
EcoCool is manufactured from clean, unused cardboard offcuts and features a structure designed to absorb shock and maintain its shape during transportation. According to Hydropac, this enables the liner to provide both thermal protection and cushioning within a single packaging component.
The company has tested EcoCool as part of a complete packaging system, incorporating the liner, coolant and product to replicate actual shipping conditions. In one laboratory trial, a large box containing EcoCool, a product and coolant was held for 48 hours in a temperature-controlled chamber cycling between approximately 20°C and 25°C. Hydropac reported that the product’s surface temperature remained below 8°C throughout the test.
“Sustainable insulation is only sustainable if it works,” said Colin Rowland, Managing Director, Hydropac. “There are plenty of low-cost paper options that look the part, but the question any packaging team should ask is whether the whole box, liner and coolant together, protects the product on a real route. We’ve engineered EcoCool around that question.”
Hydropac has also confirmed that EcoCool has undergone independent laboratory testing to assess its technical recyclability in a conventional recycling mill. The company reports that the tested constructions achieved high screening yields, receiving a ‘Best in Class’ classification in October 2026.
The liner has also received a green rating under the UK’s Recyclability Assessment Methodology (RAM), which is used to assess packaging recyclability under Extended Producer Responsibility (EPR) regulations.
EcoCool is produced using a dry manufacturing process, without added glue or water, and Hydropac states that production is powered entirely by renewable electricity. The liner is designed for kerbside recycling.
“Cushioning and insulation have usually meant two different materials. EcoCool does both as a paper-fibre liner,” added Rowland. “Our advice to brands is simple – don’t just swap the liner, look at everything that goes in the box. We’ll help them test it with a coolant and their own product so they can have complete confidence before switching.”
The new liner can be used alongside Hydropac’s existing coolant products, including its HydroPure water ice packs. The company is also offering customers testing support to establish suitable combinations of liners, coolants and boxes for their individual products, delivery routes and temperature requirements.
EcoCool is scheduled for general release on 12 November 2026, with early access available to registered businesses from 4 November.
