Here we will go through the various options, and highlight the pros and cons of each thermal cover variant.

There are many different size of thermal covers available including covers for large airfreight pallets.

We will start with the standard size pallets that are commonly used in the UK and Europe and the U.S.

Standard sized pallets

We will look at standard pallet sizes which are widely used for all types of transport, and can be loaded on air freight PMC pallets and inside shipping containers.

There are two sizes used in the UK, 1200mm x 1000mm and 800mm x 1200mm. Other countries have other sizes in use.

We are talking UK and EURO size transport pallets as shown below.

The thermal covers are available for different load heights and some are supplied with base sheets that seal to the thermal cover to provide a sealed thermal barrier as shown below.

The base sheet seals to the cover using double side adhesive tape that is part of the base sheet. the operator peels off the backing tape and sticks the base sheet to the pallet cover as shown. This improves the effectiveness of the thermal cover.

The following types of thermal covers are available for standard pallet load sizes.

Black cloth quilted thermal fibre filled cover

This cover is reusable with Velcro style tape on each corner for ease of use. 

This cover has a fibre fill wadding sandwiched in between polyethylene fabric.

PROS: It is very flexible and easy to apply and remove, and to fold up.

CONS: It is not waterproof, and it will show dust and dirt, and it is not easy to wipe down or clean. By contrast a foil cover can be wiped clean if needed.

APPLICATION

These covers are reusable so ideally you would want to keep them on site, or use them to protect deliveries in situations where the driver can remove the covers and bring them back to base.

For situations where the palletised load is not exposed to radiant heat from direct sunlight then these covers will work well.

Foil thermal pallet covers

This cover is not designed to be reusable, and it is not recyclable. There are two main types of foil covers; SINGLE sided and DOUBLE sided. The illustration above shows the DOUBLE sided layers. The SINGLE sided does not have a foil layer on the INSIDE face.

The SINGLE sided foil cover is cheaper and marginally less effective, but fit-for-purpose for many applications. It is worth trying this as an option first as it still a very effective thermal barrier.

PROS: Cost effective. It doesn't take much storage space. Lightweight and waterproof.

CONS: Not reusable. Not breathable unless specified.

APPLICATION

This cover is ideal for one-way trips where the cover cannot be returned. It is waterproof so will keep goods dry. It can be used in conjunction with gel ice packs to help maintain low temperatures.

For single use applications where you need to keep refrigerated goods between 2 - 8 degrees Celsius, or have products such as wax candles which are susceptible to damage from temperature spikes.

During transit, ambient temperatures will peak and trough, and the thermal foil cover slows the rate of temperature change reducing fluctuations in temperature which means temperature sensitive products are less exposed to temperature extremes.

Thermal radiation or radiant heat from direct sunlight will cause a rapid increase in temperature to exposed goods. The foil barrier will reflect the vast majority of this heat again helping to ensure temperature stability.

Fibre filled thermal pallet covers

This thermal cover does not have a base sheet and is reusable having Velcro style tape on the corners making it easy to apply and remove.

The multilayer construction provides very effective thermal protection. There are two layers of non-woven material as well as a fibre fill layer and foil inside and out.

Here you have the combined benefits of the quilted fibre fill cover, and the foil cover, and it is ideal for keeping things cool (or warm) on site.

An real life example is a popup bar at a music festival using this cover to keep ice cubes frozen for 5 days.

As this cover is reusable and relatively expensive compared to the foil thermal covers which are generally single use.

Recyclable, waterproof and breathable

This thermal cover produced by TLX Cargo can be recycled, is breathable and waterproof allowing the exchange of air and water vapour through the material, this helps the internal moisture levels within the pallet not to reach harmful levels.

This technology is combined with a brilliant white outer skin which reflects the greatest amount of the visible spectrum solar radiation possible, one of the most important factors responsible for temperature excursions during transportation.

A benefit of this cover is its breathability which allows ethylene from ripening fruit to vent out from the palletised load, thereby extending the usable life of the fruit.

The blog up to now has discussed options for standard size pallets.

Typically air freight pallets require single use thermal covers as the sender is unlikely to be able to arrange the return of the covers from remote locations.

Typically the economical single sided foil thermal cover is used to keep costs and weight down, and the cover provides thermal protection from direct sunlight during ''tarmac time', and it is waterproof providing protection from the weather.

As an alternative to wrapping an air freight pallet with foil lined bubblewrap which is time consuming, the thermal foil cover only takes about 2 minutes to apply, and will  reduce labour costs.

Hopefully this blog will help you to understand the options available for protecting your perishable goods.

If you have any further questions please CONTACT US.