THERMOCON / FOAM BRICKS
Foam Bricks: coolant packs that keep their shape
Foam Bricks are suitable for temperature-controlled shipping of pharmaceutical and biotech products, as well as food. Their foam core helps them retain their shape even when frozen, allowing reliable, repeatable positioning in the insulated box. The core also reduces the risk of leakage if the pack is damaged.
THREE COOLANT OPTIONS
Which melting point suits your shipment?
The melting point describes the coolant, not the product temperature. To select a suitable option, consider the required temperature, shipping duration, insulated box and pre-conditioning together.
Water-based · 0 °C
For shipping fresh products in appropriately designed insulated packaging. Can also be used for +2 to +8 °C when the pack configuration and pre-conditioning are matched to the products.
PCM 5 · +5 °C
For applications at +2 to +8 °C. The phase change at around +5 °C allows the material to absorb or release heat within this temperature range.
PCM −21 · −21 °C
For suitably designed frozen shipping systems, for example at −15 to −25 °C. Can offer an alternative to dry ice, depending on the shipping requirements.
The melting point is not the product temperature. Temperature control and shipping duration depend on the complete packaging configuration, not on the Foam Brick alone.
FOAM CORE IN A FILM POUCH
A consistent shape makes packing more predictable.
A Foam Brick consists of a foam core that absorbs the coolant, enclosed in a PA/PE laminate film pouch. The core maintains the pack’s shape both when frozen and when thawed.
This makes it easy to position and stack the packs or slide them into designated slots. The packing instructions can specify exactly where the coolant packs should be placed.
The foam core holds the coolant and can reduce leakage if the film is damaged. This provides additional protection, but the outer pouch must still be intact.
Foam Bricks are mainly used in single-use shipping processes. Where fixed dimensions are needed, they are often a cost-effective alternative to hard-shell coolant packs.
DIMENSIONS AND FILL WEIGHTS
Standard sizes at a glance
The figures below show fill weights and dimensions in the order length × width × height. On the product page, select the melting point, available size and quantity for your enquiry.
Foam Brick · 0 °C
Water-based filling
250 g
152 × 95 × 20 mm
500 g
195 × 130 × 21 mm
520 g
136 × 136 × 30 mm
630 g
177 × 102 × 39 mm
680 g
120 × 100 × 60 mm
1,100 g
280 × 190 × 25 mm
1,690 g
286 × 236 × 27 mm
Foam Brick PCM −21
Melting point approx. −21 °C
460 g
195 × 130 × 21 mm
520 g
136 × 136 × 30 mm
630 g
177 × 102 × 39 mm
660 g
120 × 100 × 60 mm
1,300 g
280 × 190 × 25 mm
1,600 g
280 × 190 × 30 mm
1,750 g
286 × 236 × 27 mm
Other sizes and Foam Bricks with PCM 5 are available on request. Tell us the available space and the quantity you need.
PCM 5 / MELTING POINT +5 °C
Foam Bricks for +2 to +8 °C
PCM 5 combines a foam core that retains its shape with a phase change material that melts at around +5 °C. The material absorbs heat as it melts and releases the stored heat as it solidifies.
In appropriately designed packaging, PCM 5 can be used in a year-round packout. The system and packing instructions specify whether pre-conditioning can also remain the same in summer and winter.
We can help you choose the available size, fill weight and preparation procedure for your application. Replacing water-based Foam Bricks with PCM 5 requires a review of the complete configuration.
MORE SIZES AND PACK FORMATS
Compare coolant packs in the finder
Narrow down the options by transport temperature, pack format and coolant. For this product group, select Foam Bricks as the pack format in the coolant pack finder.
If the size or PCM 5 variant you need is not listed, contact us directly. The standard product data are also shown in the size overview on this page.
FROZEN SHIPPING
When can PCM −21 replace dry ice?
For suitable applications at −15 to −25 °C, Foam Brick PCM −21 can offer an alternative. It does not reach the very low temperature or high energy density of dry ice, so it is not a general substitute for products requiring much lower temperatures.
THERMOCON PCM −21 Foam Bricks are not classified as dangerous goods. The requirements that normally apply to dry ice as a coolant therefore do not apply to these packs. Requirements for the goods being shipped, the mode of transport and the carrier still need to be checked separately.
The packs can be kept in stock and prepared in a suitable freezer. There is no loss of coolant through sublimation, making preparation less dependent on a last-minute dry ice delivery.
FOOD / PHARMA / E-COMMERCE
Coolant packs that retain their shape for consistent packing
Food and fresh produce
Water-based Foam Bricks for chilled goods, PCM −21 for suitable frozen shipments: choose the filling and quantity to match the temperature requirements and packaging.
Film options suitable for direct food contact are available. Product-specific compliance documentation can be supplied on request.
Pharma and biotech
The consistent shape makes it easier to specify pack positions and quantities in the packing instructions. Together with the insulation and pre-conditioning requirements, this allows the packout to be reproduced reliably.
Foam Bricks can form part of pre-qualified systems and shipping processes designed around GDP requirements. An individual coolant pack is not a qualified complete system.
E-commerce and mail order
Consistent pack sizes make it easier to standardise workflows, even when staff or shipping volumes change.
Illustrated packing instructions can show which packs to use and where to place them. Staff still need the appropriate training, and the process needs to be monitored.
For specified variants and applications, documentation relating to Regulations (EC) No 1935/2004 and (EU) No 10/2011 can be provided. Refer to the documentation approved for your variant and its food contact conditions.
PREPARATION / STORAGE / PACKING
How to pre-condition Foam Bricks
1. Prepare the coolant
For applications that require a solid starting state, the coolant must be fully frozen or solidified. Preparation time and procedure depend on the filling, pack size, air circulation and freezer capacity.
2. Prepare for packing
A pack taken directly from a freezer may be too cold for sensitive products. Where specified, a controlled tempering step follows. Follow the packing instructions for the particular configuration.
3. Inspect and pack
Check the film, seals and shape. Then place the specified number of packs in their designated positions. Preparation also includes ensuring the correct starting temperature of the products.
PCM −21: THERMOCON gives freezer temperatures of around −30 to −40 °C as an example. The required duration and any subsequent tempering are defined for each application. These temperatures do not automatically apply to PCM 5.
Storage: Store unfrozen packs in a dry place, protected from prolonged direct sunlight and mechanical damage. Follow the relevant storage and packing instructions for pre-conditioned packs.
SIZE / FILLING / PRINTING
Foam Bricks tailored to your packaging
Foam Bricks can be made to custom dimensions with relatively low tooling costs. Custom printing on the film is available, subject to a suitable minimum order quantity.
Custom coolants or PCM formulations can also be assessed. We match the melting point, foam core, film and dimensions to the requirements; availability of a given melting point depends on the pack format.
To help us design a suitable solution, tell us the available internal space, required product temperature, shipping duration, ambient conditions and quantities needed. A sketch of the packaging is a useful starting point.
FOAM BRICK / GEL PACK / HARD SHELL
Which pack format suits your packing process?
Foam Bricks
A foam core maintains the shape and holds the coolant. Suitable where the packaging requires packs to occupy defined positions and areas. Mainly used in single-use processes.
Gel packs
A gel-filled film pouch without a foam core to maintain its shape. When freezing the pack, allow for the shape needed during packing. Available with different fillings and in various sizes.
Hard-shell coolant packs
A robust shell for repeated use. A suitable choice when returns, cleaning and pre-conditioning are established parts of the shipping process.
The most suitable pack format depends on the application. As well as unit costs, consider pre-conditioning, packing time, insulation and whether the packaging will be used once or repeatedly.
COOLANT PACK + INSULATED BOX
Design the complete packaging system
The size, number and position of the Foam Bricks must fit the internal space of the insulated box and its payload. Our range includes EPS insulated boxes and paper-based insulated packaging.
If you need a tested combination with defined temperature control, explore our pre-qualified systems. For custom requirements, our thermal engineering team can help with design and testing.
PRACTICAL QUESTIONS
Frequently asked questions about Foam Bricks
What is a Foam Brick?
A Foam Brick is a coolant pack with a foam core inside a film pouch. The core holds the coolant and maintains the pack’s shape. THERMOCON offers water-based fillings, PCM 5 and PCM −21.
Are Foam Bricks completely leakproof?
The foam core can reduce leakage if the film is damaged, but it does not guarantee that a damaged pack will remain leakproof. Damaged packs should not be used for shipping.
How long do Foam Bricks keep products cool?
There is no single duration that applies to every shipment. The filling, coolant mass, insulated box, payload, pre-conditioning and ambient temperatures all affect temperature control. We can test a specific shipping configuration in our climate chambers.
Can Foam Bricks be reused?
Foam Bricks are mainly used in single-use processes. Limited reuse is possible with careful handling, provided the film and pack are undamaged and the hygiene requirements and approved process allow it. No fixed number of reuse cycles is guaranteed for all applications.
Can Foam Bricks come into direct contact with food?
Film options suitable for direct food contact are available. Suitability applies to the documented variant and the specified contact conditions. Please describe the intended contact when you enquire.
Can I replace water-based Foam Bricks with PCM 5?
The configuration must be reviewed first. Different melting points require suitable pre-conditioning and may call for a different coolant mass or pack configuration. Even packs with identical external dimensions have different thermal characteristics.
What information do you need for a custom size?
Please provide internal dimensions or a packaging drawing, the required temperature, shipping duration, ambient conditions and planned quantity. For custom printing, we also need the artwork specifications.
How should Foam Bricks be disposed of?
Follow the instructions for the supplied variant and local waste disposal requirements. The foam core, film and filling should not be assumed to form a single recyclable material.
Which Foam Bricks do you need?
Tell us the filling, size and quantity you need. For the thermal design, we also need details of the product, temperature range, shipping duration and packaging.