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DS Smith partners with Brrr Box to deliver sustainable, recyclable Styrofoam cooler alternative

Greencoat's moisture and temperature-resistant technology makes Brrr Box the first commercial, sustainable Styrofoam cooler alternative.

DS Smith has joined forces with Vig Pak LLC to introduce Brrr Box, a patented, 100% recyclable, biodegradable cooler that incorporates some of the most modern technologies available in corrugated cardboard packaging.

Named “The Official Cooler of Planet Earth,” Brrr Box uses DS Smith’s proprietary Greencoat corrugated moisture-resistant and FDA food contact-safe material to coat its Styrofoam alternative.

Unlike typical plastic foam coolers, Greencoat is biodegradable, made of sustainable and renewable fiber that reduces waste to landfills and carbon emissions.

“Greencoat launched 13 years ago as a revolutionary product created to survive the harsh poultry shipping supply-chain and has since been adopted by a number of other markets. Brrr Box is a natural extension of the product line that’s ideal for consumers looking for an eco-friendly, durable way to transport ice and cold beverages without the negative impact of Styrofoam,” said Melanie Galloway, sales, marketing and innovation director at DS Smith Packaging North America.

She announced the partnership today with Brrr Box co-founder and President Ed Battle.

Battle said that Brrr Box is an innovative corrugated beverage cooler solution and is being used by a major U.S. convenience store chain to replace Styrofoam coolers.

“The chain was looking for a disposable cooler that performed as well as Styrofoam first and foremost,” he said. “They are also conscious of precious floor space in stores, and Brrr Box is shipped and displayed flat, so they can carry more inventory in a much smaller footprint. And, frankly, they wanted an environmentally friendly alternative as well. Brrr Box is the only product that does that.”

Battle said it’s not a single-use cooler. “It’s a multi-use cooler if treated properly. And the best part is instead of those Styrofoam coolers going back into the waste stream, this goes back into the circular economy and is fully curbside recyclable,” he said.

Galloway said Greencoat uses a patented process applied completely in-house, The technology combines impregnation and coating on the paper to provide durability and long-lasting moisture protection and temperature resistance.

For retailers looking to provide an eco-friendly alternative to Styrofoam, Brrr Box offers many benefits, including:

  • 100% recyclable and biodegradable.
  • Ships and merchandises flat.
  • Accepts high-impact graphic printing.
  • Reduces freight, warehousing and merchandising space.
  • Compatible with corporate green initiatives and reduces carbon footprint.
  • Opens and closes with one hand and assembles in about 5 seconds.
  • Cooler holds a dozen 12-ounce beverages and 10 pounds of ice. Can keep contents cold for up to 8 hours.
  • Made in the United States.

DS Smith’s purpose is to ‘Redefine Packaging for a Changing World’, and as part of its recently launched “Now and Next Sustainability Strategy,” DS Smith by 2030 will use packaging and recycling to replace problem plastics, reduce customer carbon and eliminate consumer packaging waste.