When to Use pallet top covers？

Insulated pallet covers are crucial for shipping temperature-sensitive goods across industries such as pharmaceuticals, agriculture, and chemicals. They help extend shipping times, reduce transportation costs, and protect products from extreme ambient temperatures, ensuring safe and efficient delivery.

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What are thermal pallet covers?

Thermal pallet covers, also known as insulated pallet covers, are specially designed covers designed to be placed on top of pallets of goods to protect temperature-sensitive goods such as pharmaceuticals, chemicals, and agricultural products from extreme temperatures during transportation. These covers create a thermal barrier, shielding the contents from heat, cold, and sudden temperature fluctuations.

For enhanced protection, a slip sheet can be used to fully enclose the pallet, ensuring consistent temperature regulation throughout the shipment. Standard sizes are available to fit most pallets, with options for custom sizing to meet specific shipping needs.

IPC manufactures insulated pallet covers using our CooLiner materials which combine an ultra-radiant barrier and a super-insulating bubble layer. The covers help prevent heat damage in cross-dock shipping and on the tarmac. CooLiner's dual layer provides the strength and flexibility needed to resist punctures and withstand rigorous handling during transit, while also blocking light, UV, and odor transfer. The pallet covers are available with a bottom layer for full product enclosure, and each comes with easy peel-and-seal closures.

Thermal pallet covers are widely used across industries where maintaining temperature control is crucial, including food, beverage, pharmaceutical, and chemical logistics.

Standard sizing for Pallet Covers is 48” x 40” x 48”, 48” x 40” x 60” , 48” x 40” x 72, and 48” x 40” x 96”. IPC manufactures custom Insulated Pallet covers to your specifications which can accommodate taller or wider non-standard pallets.

What's the difference between insulated pallet covers and standard pallet wraps?

Insulated Pallet Covers or thermal pallet covers are designed to protect the contents atop the pallet from temperature. Regular pallet covers can range from shrink wrap and other poly plastics that can protect the boxes from water and tears. CooLiner is also puncture resistant and can create a watertight seal when used with our slip sheet. While pallet wraps and covers can protect from physical damage like tears and water, an insulated pallet cover provides extended shipping times which is critical to preserve product quality and safety, and reduce operating costs.

Can insulated pallet covers prevent product damage during transit?

Our insulated pallet covers area also puncture resistant and can create a waterproof seal when used with our slip sheet.

Can insulated pallet covers be custom-made for specific applications?

Yes, we manufacture custom insulated pallet covers for clients with particular needs that might warrant a different weight of our high performance bubble insulator and non-standard dimensions.

How do pallet covers help with temperature-sensitive shipments?

By enclosing the pallet in a high-performance thermal radiant barrier, products are effectively insulated from external ambient temperatures, significantly slowing down the rate of temperature change and dampening the effects of fluctuating external conditions, whether heat or cold.

Use a slip-sheet underneath the goods to create a protective "cocoon" around the goods to reduce the speed at which the product's temperature adjusts to its surroundings, allowing it to maintain its internal temperature for a longer period. This delay in reaching thermal equilibrium, or homeostasis, with the ambient environment is crucial for preserving the integrity of temperature-sensitive goods, particularly during transport and storage, where external conditions can vary widely.

What industries use thermal pallets?

So thermal pallets are common in pharmaceuticals, agriculture for keeping temperature, pharmaceutical and agriculture for keeping temps low. And they are also used for protecting against packages getting too cold in water-based chemicals.

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Insulated Pallet Covers in Pharmaceutical Distribution

Insulated pallet covers are essential in pharmaceutical distribution, protecting temperature-sensitive medications and vaccines from external heat and cold during transit. They help maintain regulatory temperature standards, ensuring product efficacy and safety. Additionally, insulated covers reduce the need for refrigerated transport, lowering shipping costs while preserving quality.

Insulated Pallet Covers in Agriculture

Insulated pallet covers are vital in agriculture, keeping perishable products like produce and dairy at stable temperatures during transport. They protect goods from temperature fluctuations, preserving freshness and quality. By reducing the need for refrigerated transport, these covers help lower shipping costs while maintaining product integrity.

Are thermal pallet covers reusable?

Yes, some insulated pallet covers are reusable, particularly those made from durable materials like PVC and nylon. These are ideal for companies with closed-loop logistics systems where retrieving the covers is feasible and cost-effective. However, single-use insulated pallet covers are more common in businesses with complex logistics, where recovering the covers is impractical. Reusable pallet covers can cost upwards of $400, with some ranging between $150 to $250, while single-use covers are typically much cheaper, ranging from $15-25 a piece.

How do pallet covers reduce energy costs in shipping?

Insulated pallet covers offer a passive cooling solution that can reduce or eliminate the need for energy-intensive refrigerated trucks. The natural thermal mass of large pallets helps maintain stable temperatures, and insulated covers enhance this, providing sufficient temperature protection for many shipments. This switch can lead to significant cost savings, as refrigerated trucks typically consume 20% more fuel and come with higher upfront and insurance costs compared to non-refrigerated options.

Example of Costs Differences for Reefer vs Dry Transport

From CA to Dallas, TX 1 FTL dry van = $4,300 1 FTL reefer van 41 degrees temperature = $4,800 Price Difference = $500 Estimated Cost of 26 Pallet Covers @ $15/unit = $400

From CA to Union City, NJ 1 FTL dry van = $6,900 1 FTL reefer van 41 degrees temperature = $7,800 Price Difference = $900 Estimated Cost of 26 Pallet Covers @ $15/unit = $400

As the volume and distance of your product increase, single-use insulated pallet covers make more and more sense.

Insulated pallet covers also offer the flexibility to ship mixed products within the same truck by isolating items that require different temperature conditions. This reduces the need for dedicated refrigerated trucks, optimizing truck space and cutting down on transportation costs. Additionally, these covers help extend the shelf life of temperature-sensitive goods by maintaining stable conditions during transit, which reduces the risk of spoilage. By ensuring that products arrive in optimal condition, businesses can minimize losses, avoid refunds, and improve their overall profitability.

Choosing the right insulated pallet cover

If you're in the pharmaceutical, agricultural, or water-based chemical industries, insulated pallet covers are likely essential for protecting your shipments. When selecting the right pallet covers, your primary considerations will be performance and cost. You can choose between single-use covers or reusable, machine-washable options. However, if you're shipping nationally through freight forwarders or multiple distributors, recovering reusable pallet covers may be challenging or impractical, making single-use covers a more feasible solution.

How to put on an Insulated Pallet Cover

1. Step 1: Prepare the Pallet - Ensure that the pallet is fully loaded and securely packed. All items should be neatly arranged and stabilized to prevent shifting during transport. If you're using any slip sheets or other protective materials, make sure they are properly in place, we recommend the slip sheet of insulation being placed on pallet before goods are stacked on top.
2. Step 2: Unfold the Insulated Pallet Cover - Carefully unfold the insulated pallet cover. Ensure the cover is the right size for your pallet—most covers come in standard sizes, but custom sizes may be necessary depending on your load.
3. Step 3: Position the Cover - Start by opening the open corner to position the cover so that the top face is centered over the top of the pallet. Start by draping the cover over the pallet's top face, ensuring that it evenly covers all edges.
4. Step 4: Lower the Cover Over the Sides - Once the cover is centered on top, begin lowering it over the sides of the pallet. Gently pull down on each side to ensure that the entire pallet is covered evenly. The cover should extend down to the base of the pallet, protecting the sides from temperature fluctuations.
5. Step 5: Smooth Out and Adjust the Cover - Smooth out any wrinkles or creases in the cover to ensure a snug fit. Properly adjusting the cover helps maintain the thermal barrier, minimizing gaps where air or heat could penetrate.
6. Step 6: Tape the Side Flap - With one side face open, peel the tape seal and stretch the side face of the liner over the remaining open side face. Make sure to keep the pallet cover aligned to the edges of the pallet when pulling the final face of the cover. After overlapping onto the exposed adhesive, push the overlapping edge to ensure adhesion.
7. Step 7: Optional: Use a Slip Sheet for Full Enclosure - If you want full insulation for your pallet, including the bottom, you can add a slip sheet underneath the pallet. Place the slip sheet before loading the pallet, and then cocoon the entire pallet by folding the slip sheet up over the bottom edges and onto the top cover. This can be performed by folding the slip sheet up after peeling away the tape peel & seal and tape the edges to the sides of the pallet to fully enclose the pallet.
8. Step 8: Double-Check the Fit - Once the cover is in place, double-check that all sides are properly enclosed and that the cover fits securely. Ensure there are no exposed areas that could allow temperature changes to affect the goods.

Your pallet is now insulated and ready for shipment. The insulated pallet cover will help maintain a consistent temperature for your products, protecting them from external environmental factors during transport.

Pallet covers, also known as pallet wraps or pallet shrouds, are a type of protective packaging material used to secure and protect items on a pallet during storage and transportation. Pallet covers come in a variety of sizes and can be used in a range of industries including retail, manufacturing, and logistics. Plastic pallet covers provide a barrier between your goods and the elements, protecting them from weather-related damage. They can keep your products dry during rainy seasons and prevent damage from wind, snow, or hail. This is especially important for businesses that transport goods outdoors or in areas prone to extreme weather.

In this article, we will explore 9 compelling reasons to use pallet covers in your business operations.

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1. Improved product protection: Pallet covers provide an extra layer of protection for the products on a pallet, helping to prevent damage during storage and transportation against moisture, dust, ultraviolet (UV) light and other environmental factors that can compromise the quality of your goods. This is particularly important for fragile or delicate items that may be susceptible to damage from shifting, moisture, or other environmental factors. This can help to ensure that your products arrive at their destination in the same condition as when they were shipped, which can improve customer satisfaction and reduce returns.
   
   
2. Enhanced security: Pallet covers can help to secure the items on a pallet, making it more difficult for unauthorized individuals to access or tamper with the contents. This added security can help to reduce the risk of theft or damage during transit. Pallet covers plastic can provide an additional layer of security for your goods during transport. This is especially important for businesses that transport high-value or sensitive goods.
   
   
3. Increased stability: Pallet covers can help to keep the items on a pallet stable and secure, reducing the risk of shifting or movement during transit. This added stability can help to prevent damage to the items on the pallet and ensure that they arrive at their destination in good condition. Pallet covers can also help to increase the stacking strength of your goods. When items are stacked on a pallet, the weight can cause them to shift or compress. Pallet covers help to distribute the stacking weight evenly across the entire pallet.
   
   
4. Enhanced presentation: Pallet covers can improve the presentation of your products, helping to create a professional and organized appearance. This is particularly important for businesses that are looking to impress potential customers or clients with their products and packaging.
   
   
5. Improved handling and loading: Pallet covers can make it easier to handle and load pallets, as the covers provide a smooth and even surface for forklifts and other handling equipment to grip. This can help to reduce the risk of damage to the items on the pallet, as well as improve efficiency and productivity during loading and unloading operations. They provide a convenient and secure way to keep your products together, which can help to reduce the risk of damage and make it easier to move your goods from one location to another. This can save time and effort, and help to improve the efficiency of your operations.
   
   
6. Cost savings: Pallet covers can help to reduce the overall cost of packaging and transportation, as they provide an effective and cost-efficient alternative to traditional protection from weather and environmental elements.
   
   
7. Enhanced Sustainability: Using pallet covers can also help to support sustainability and environmental responsibility. Many pallet covers are made from recycled materials, which can help to reduce waste and minimize your impact on the.
   
   
8. Enhanced product visibility: Pallet covers can provide clear visibility of your goods, allowing for easier identification and inventory management. This is especially important for businesses that transport large quantities of goods, as it can help to ensure accurate tracking and inventory control.
   
   
9. Improved load stability: Pallet covers help to keep your goods securely in place on the pallet, reducing the risk of shifting or falling during transportation. This can improve the overall stability of your load, making it easier to move and handle. Pallet covers can also provide added support to help prevent damage to your goods due to rough handling or rough road conditions.