Introducing the First Ever Thermal Insulated Mailer Envelope with Integrated PCM Refrigerants

Pre-qualified parcel mailer provides temperature stability for last-mile pharmaceutical delivery without needing a cooler and separate gel packs

thermal insulated mailers

The increasing demand for temperature-controlled packaging necessitates a lower-cost solution that is cost-effective and better for the environment.

The first-of-its-kind thermal insulated shipping mailer envelope integrates PCM refrigerants into its construction, allowing specialty pharma and mail-order drug organizations to send individual doses of medications at a stable room temperature with an envelope form factor. The patent pending solution removes the need for EPS coolers, a corrugated box, and separate refrigerants by integrating a proprietary phase change material (PCM) into the lining of the mailers and envelope:

  • Reduces shipping costs and minimizes the space required for CRT shipments
  • Reduces pack-out error by simplifying the packing process since there is only one fully cohesive component
  • Decreases packaging waste as no cooler or corrugate box is required
  • Envelopes are vacuum sealed and shipped in compressed bundles, which allows companies to stock inventory with ease until ready to use

PCM Refrigerant Built into The Envelope

The thermal insulated mailers contain a Phase Change Material (PCM) selected for the specific temperature it maintains when transitioning between its solid and liquid states. 

In this case, the summer mailer incorporates a 23°C PCM which will change from solid to liquid to protect from extreme heat, while the winter mailer utilizes a 5°C PCM that will change from liquid to solid to protect from extreme cold.

Durable Construction

The insulated shipping envelopes use layers of PCM enclosed within open-cell Polyurethane insulation in a PE bag to protect the payload. The PCM is arranged in a mat format allowing the mailer to be flexible even in its solid state, making it ideal for parcel delivery at the lowest possible cost.

*When compared to other solutions on the market today 


Qualified To the ISTA 7E Standard for URAC Requirements

Controlled room temperature (CRT) regulations and requirements are traditionally defined as 20–25°C, with allowable excursions of 15–30°C, as long as their mean kinetic temperature remains in the specified range. 

Recent URAC requirements have a potential CRT range of 2-30°C if the drug stability supports it per USP 659.

TempAid thermal insulated PCM Mailers Envelope  are tested against the ISTA 7E Summer, Winter, and Intermediate profiles using lane data gathered from real-world conditions and tested with several different product payload boxes and instrumented with calibrated RTD temperature monitors.

Quick Specs

ISTA 7D & 7E Profiles AvailableSummer, Winter, Spring/Fall
Outer Dimensions15” x 12” x 3”
Inner Payload DimensionsApprox. 5” x 4” x 2”
Qualified Temperature Ranges

15°C – 25°C for 48 hours (Summer)

2°C – 30°C for 144 hours (Summer, Winter and Spring/Fall)

Custom ranges available upon request

CustomizableCustom branding available
Unit Weight2 pounds
ShippingShipped in vacuum compressed bundles to enable less storage space

This product is patent pending