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IntegriTemp, a division of Plastilite Corporation, will introduce a new cold-chain mailer on October 18 at PACK EXPO International 2026. The Thermalast Mailer™ and the innovative Ice-Chubz™ gels are a new mailing system engineered to keep temperature-sensitive products in the critical 2°C–8°C refrigerated range longer during shipment.
Developed for companies mailing pharmaceuticals, supplements, biologicals, injectables, vaccines, food and other temperature-sensitive products, the new solution solves the biggest problem in cold-chain mailing; ensuring your product stays in the safe range, not necessarily just keeping the ice packs cold or frozen.
The Thermalast Mailer complements the Ice-Chubz design with an inner liner that reflects cold back toward the product, extending mailing time while maintaining the desired temperature range.
Ice-Chubz TM feature a broader cylindrical profile facing the product. This design allows more cold to surround the payload as opposed to a traditional flat gel pack which releases most of its cooling power into the insulation.
Performance testing demonstrated the potential impact of the new system. Depending on the payload, two 24-ounce Ice-Chubz can improve temperature-maintenance performance by more than 50% compared with 24-ounce flat gel packs. When also paired with the Thermalast Mailer design, the combined improvement was even greater.
“We’ve had many inquiries over the years looking to source insulated mailing pouches from us, but we were never satisfied with their performance. Once we discovered why they didn’t work very well, we were able to engineer a solution that significantly improved performance to the point of being a superior alternative,” says Jon Ehly, Plastilite CEO. “We are excited to bring this unique product to the market.”
In addition to improved thermal performance, the solution was designed with practical pack-out considerations in mind. The Thermalast Mailer’s sideload pouch design provides easier access when loading the product and the Ice-Chubz, while its flat format can reduce the amount of inventory space needed when compared to other cold-chain packaging alternatives.
IntegriTemp, a division of Plastilite, will showcase the new ControliQ Thermalast Mailer and Ice-Chubz at PACK EXPO International (Chicago) Booth W-24114 beginning October 18. Samples are expected to be available at the show, with production targeted for early 2027.
