Temperature-controlled packaging specialist Hydropac (www.hydropac.co.uk), has launched EcoCool, an insulated box liner that brings thermal insulation and cushioning protection together in one single product.
The new paper-fibre liner is an alternative to traditional insulation such as polystyrene, loose paper fill, cotton, jute and wool and is available for use inside 10", 12" and 14" cubed box systems.
EcoCool's unique structure is designed to absorb shock and keep its shape in transit. So, as well as maintaining optimum levels of thermal insulation, the liner protects cold chain goods from physical damage and importantly, also provides a clear and credible recycling route at end of life.
Tested as a complete system
Hydropac has extensively tested EcoCool in a 'real-life' complete box scenario, with the liner, a coolant and product packed together as they would be for an actual delivery.
One example in Hydropac's own laboratory, saw a large box lined with EcoCool and packed with a product and coolant. It was held for 48 hours in a chamber cycling between roughly 20°C and 25°C, and the product surface temperature stayed below 8°C throughout.
For each customer interested in switching to EcoCool, the Hydropac team has committed to help them calculate the right combination of liner, coolant and box for their product, delivery route and temperature requirement, and will test it all with them before they decide to switch.
Material choice and EPR
Hydropac believes insulation shouldn't leave a difficult problem behind. EcoCool has been independently laboratory tested for technical recyclability in a conventional recycling mill, with the tested constructions achieving high screening yields classified as “Best in Class” in October 2026.
Under the UK's Extended Producer Responsibility rules, packaging material affects what brands pay. Under the illustrative 2026/27 fees published by the UK government, plastic packaging is charged at £415 to £545 a tonne, and paper and board £190 to £250 a tonne, figures which demonstrate further environmental and performance benefits of EcoCool, now with financial disposal benefits too.
EcoCool is also rated green under the UK Recyclability Assessment Methodology (RAM), the system used to assess how recyclable packaging is under EPR.
Colin Rowland, Managing Director at Hydropac, said:
"Sustainable insulation is only sustainable if it works. 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."
He added:
"Cushioning and insulation have usually meant two different materials. EcoCool does both as a paper-fibre liner. 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."
EcoCool is made from clean, unused cardboard offcuts and is designed for kerbside recycling, backed by independent recyclability testing. The product is manufactured using a 100% dry production process, with no added glue or water, and what's more, production is completely powered by renewable electricity.
The new paper-fibre liner pairs perfectly with Hydropac's existing range of coolants, including HydroPure water ice packs, as part of a complete temperature-controlled packaging system. Brands using other coolants can speak to Hydropac's experts about how EcoCool could work within their existing set-up.
EcoCool goes on general release on Thursday 12th November 2026. Businesses that register their interest get early access from Wednesday 4th November. Registration is open now on the Hydropac website.
About Hydropac
Hydropac is a leading provider of temperature-controlled packaging solutions, specialising in the design and manufacture of insulated packaging and water-based coolants. With 25 years in temperature-controlled packaging, Hydropac is the innovator behind EnviroCool, ReflectiveAir, Recycle-Air and now EcoCool. The company serves food and drink, retail and other specialist sectors, and is trusted by companies including Butternut Box and Parsley Box.