- Flagship product
- 87% smaller than EPS
- In stock
Pop Up Pouch®
A self-inflating thermal mailer with an innovative layer of protection — up to 1⅜ in of expanded foam for absolute security and superior thermal performance, whether you're shipping across town or across the globe.
- 6×
- Foam expansion
- 87%
- Smaller than EPS coolers
- 1–1⅜in
- Expanded foam wall
- Frozen−20°C / −4°F
- Refrigerated2–8°C / 36–46°F
- Controlled Room Temp15–25°C / 59–77°F
Product details
| Product | Pop Up Pouch® |
|---|---|
| Format | Integrated expanded-foam thermal mailer |
| Stock sizes | 9" × 11" · 12" × 14" · 14" × 14" · 14" × 18" |
| Foam thickness | 1 in or 1⅜ in |
| Side Seal | Patented Side Seal version available |
| Expansion | 6× when punctured |
| Activation | Seal the adhesive strip, puncture with a pen |
| Closure | Self-adhesive strip — no tape required |
| Shipped volume | 87% smaller than EPS coolers |
| Freight density | 1 truckload condensed to 3 pallets |
| Compression | Compression-tested for harsh handling |
| Custom print | Custom-printed mailer available |
| Extend hold time | Add a gel pack |
| Attribute | Pop Up Pouch | EPS cooler |
|---|---|---|
| Volume shipped and stored | 87% smaller | Baseline |
| Packaging per truckload | 3 pallets | 1 full truckload |
| Shipping cost | Cut by half | Baseline |
| Styrofoam in the supply chain | None | Every unit |
| Compression tested | Yes | Varies |
| Eco-friendly PET option | Kool Green Pop Up Pouch® | No |
Step 1
Insert
Load your items. Add a gel pack for longer temperature stability.
Step 2
Seal
Close the self-adhesive strip. No tape required.
Step 3
Puncture
A small puncture with a pen. That's the whole activation.
Step 4
It expands
The vacuum foam lining inflates to 6× its size, forming to your product.
Insert your items, seal the self-adhesive strip — no tape required — then make a small puncture with a pen. The vacuum foam lining expands to six times its size and forms itself around the product.
1 in or 1⅜ in of expanded foam surrounds the product. The Kool Green Pop Up Pouch® uses 1½ in or 2 in of expanded PET foam, and the Pop Up 1-Piece Box Liner uses 1⅜ in, 1 PCF urethane foam.
Vacuum-sealed mailers ship and store 87% smaller than EPS coolers — one truckload of EPS packaging condenses to three pallets — which is what cuts shipping costs by roughly half.
Four stock sizes: 9" × 11", 12" × 14", 14" × 14" and 14" × 18". Patented Side Seal versions and custom-printed mailers are available.
Add a gel pack alongside the payload. The foam sets the baseline; the gel extends it.
Yes. The Kool Green Pop Up Pouch® delivers the same self-expanding protection in expanded PET foam, 1½ in or 2 in thick, in the same four stock sizes.
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