PuncturePack™

Self-expanding insulated poly mailer · Compact storage · Expanded protection

PuncturePack™ combines thermal insulation and protective cushioning in an easy-to-use mailer. Delivered vacuum-compressed to save storage space, its foam expands when punctured. Simply pack, seal, and puncture to activate the expanding foam insulation.

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Two expanded PuncturePack mailers standing one behind the other on a cream ground, printed with the CentiPack logo, "Temperature stability" and puncture targets at each corner.

How it works

  1. Pack

    Place your product and the required refrigerants inside the mailer, following your selected packout instructions.

  2. Seal

    Peel off the release liner and press the adhesive flap closed.

  3. Puncture

    Puncture the outer film at the "Puncture Here" marks to release the vacuum seal and allow the foam insulation to expand.

An expanded navy PuncturePack mailer standing upright on a cream ground, its top flap folded over and sealed.

Why choose PuncturePack

  • Compact storageArrives flat and vacuum-compressed, using up to 3x less storage space.
  • Expanding insulationPU foam expands when punctured to provide thermal insulation around your shipment.
  • Protective thermal cushioningExpanded foam surrounds contents to absorb shock during handling and transit.
  • Peel-and-seal closureAn integrated adhesive strip seals the mailer quickly, with no tape needed.
  • Easy to punctureEngineered for quick, effortless puncture and efficient production line packing
  • Thermal performanceDesigned to maintain 2–8°C for 24–48 hours across a range of shipping lanes.
  • Lower shipping costsLightweight and compact, keeping dimensional weight and carrier costs down.

Sizes and specifications

Three stock envelope sizes, each available in three insulation thicknesses and a range of foam densities, give you dozens of configurations out of the box. Or we build one around your product and refrigerants.

A dimension drawing of a PuncturePack mailer: 12 inches wide by 14 inches tall measured flat, a dashed outline marking the usable payload space, and a side view labelled with an expanded thickness of half an inch, 1 inch or 1.5 inches per side.
SpecificationAvailable options
Envelope sizes9″ × 11″, 12″ × 14″, and 14″ × 18″
Expanded insulation thicknesses½″, 1″ and 1.5″ per side
PU foam densities19 kg/m³ - 32 kg/m³
Custom sizing and insulation specificationsCustom dimensions, insulation thicknesses and foam densities available upon request
Insulation materialFlexible polyurethane (PU) foam
ConstructionPoly outer film and inner liner
ClosureIntegrated self-seal strip
PrintingFull color customization and custom printing

Usable payload space depends on the selected configuration.

Tailored pack-outs

Thermal protection built around your shipment

Your product, its target temperature, and its time in transit determine the optimal packout. We work with you to select the PuncturePack™ size, insulation thickness, foam density and refrigerant configuration to help you achieve your desired shipping duration and temperature range.

Actual thermal performance depends on the complete packout, including payload, refrigerant conditioning, and external shipping conditions.

Talk to a packaging specialist
Two navy PuncturePack mailers lying open on a cream ground, flaps folded back to show their silver inner lining — one flat and empty, one expanded with its insulation inside.

Brand your mailer

Your specifications. Your brand. Your PuncturePack™.

Customize PuncturePack™ to showcase your brand. We offer full color customization, custom printing and tailored mailer specifications to support your shipping needs.

Want us to quote your custom program? Please fill out this form or contact us to discuss your optimal solution.

Request a custom quote
An expanded PuncturePack mailer standing on a cream ground, printed with a "Your logo here" placeholder.

Applications

  1. Pharmacy fulfillment

    Insulated mailers for shipping temperature-sensitive prescriptions directly to patients.

  2. Healthcare products

    Custom pack-outs for products with specific temperature and transit requirements.

  3. Testing kits & specimens

    Tailored shipping solutions for testing kits, medical samples, and specimens.

Frequently asked questions

How does PuncturePack™ expand?

PuncturePack™ arrives vacuum-compressed for compact storage. Puncturing the designated outer film releases the vacuum, allowing the PU foam insulation to expand around your shipment.

Where do I puncture the mailer?

Puncture only at the designated “Puncture Here” marks. Follow the packing instructions and avoid piercing the inner liner or contents.

What sizes and insulation thicknesses are available?

Popular envelope sizes include 9″ × 11″, 12″ × 14″, and 14″ × 18″, with custom sizes also available. Expanded PU foam insulation options range from ½″ to 1.5″ per side.

How do I choose the right size for my product and gel packs?

Allow room for your product, any inner packaging, and the required gel packs while leaving enough space to close the mailer securely. Share your payload dimensions and refrigerant requirements, and we can help recommend a size.

Can you help develop a packout for my temperature and transit requirements?

Yes. We work with you to select the mailer size, insulation thickness, foam density and refrigerant configuration for your target temperature range and shipping duration. Thermal performance depends on the complete packout and shipping conditions.

Are custom sizes and printed mailers available?

Yes. Custom dimensions and printing are available. Share your product requirements, artwork, and estimated order volume to discuss our custom program.

How can I request samples, and what are the ordering minimums?

Use the “Request a Custom Quote” button to discuss.

Thermal integrity. Validated performance. Manufacturing scale

Mass volume through our manufacturing partners — Quoted to your quantity and specifications. Low pricing guaranteed

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