Thermal box liners

At Dufaylite, we might not be in the business of supplying outer box packaging, but we’ve got the inside covered (literally). Thermal box liners, crafted from paper honeycomb board, are the go-to primary packaging solution, designed to snugly fit inside a carton. They’re not just about fitting in; they excel at keeping goods cool, fresh, and in perfect condition during transit. With first-rate insulation and robust strength, these liners ensure products arrive just as they should – fresh, intact, and at the right temperature.

To learn more about the paper honeycomb board that makes these thermal box liners exceptional, check out the Envirolite page.

More perks?

  • Kerbside recycling: Easy for consumers.
  • Quick installation: Packed in no time.
  • Eco friendly: 100% recycled paper.
  • Ultra-light: Lightest option available.
  • No odour: Stays fresh even when wet.
  • Moisture control: Manages excess moisture.
  • Cost-efficient: Saves you money.
  • Gold-standard service: Certified to BRCGS AA grade.
  • Regulation-ready: Compliant with packaging regulations.
Dufaylite paper honeycomb insulated box inner for food packaging
Dufaylite paper honeycomb eco friendly food packaging detail

Dufaylite is the only paper honeycomb provider in the world to hold the BRCGS AA Global Food Safety Standard. Envirolite food box liners are kerbside recyclable in standard paper streams and have an independently verified lower carbon footprint (CarbonQuota — see our carbon footprint study). Dufaylite is certified Carbon Neutral Britain™ and FSC® (C186880).

Independently verified carbon footprint study for food packaging

Sustainability starts with smart material choices, but it doesn’t stop there. The real test is how a product performs across its entire lifecycle. That’s why we worked with CarbonQuota, one of the UK’s leading carbon analysis experts, to measure the full cradle-to-grave carbon footprint of our paper honeycomb board liners.

The results speak for themselves:

  • 35–60% lower carbon footprint compared to lamb’s wool
  • 50–70% lower carbon footprint compared to expanded polystyrene (EPS)

Per box (for food delivery applications):

  • Paper honeycomb: 0.16–0.26 kg CO₂e
  • Lamb’s wool: 0.42 kg CO₂e
  • EPS: 0.56 kg CO₂e

These results were independently verified and certified by CarbonQuota, providing you with accurate, third-party data to support your sustainability claims, customer communications, and tender submissions.
When you choose our thermal box liners, you’re choosing food-safe packaging with high-performance insulation, complete recyclability and proven carbon savings. It’s everything you need to protect your products and your brand.

View the full Carbon Footprint Study

Envirolite: Packaging done differently

Step 1
Step 2
Step 3
Step 4

STEP 1

Let’s talk
We’ll start with a friendly chat to understand your needs. We’ll discuss your current food packaging, specific temperature targets, timeline, budget, annual order volumes, whether you require chilled or frozen products, and box sizes and volumes. No lock-ins, no hard sell (our honeycomb does that for us).
Laptop and headphones for call studio

STEP 2

We come to you
Next, one of our ‘Dufayliters’ – our green gurus – will visit your site to clarify your requirements and review your current packing processes. We’ll even take away your existing packaging to create a bespoke solution tailored to your needs.
The Dufaylite team in the Design Lab studio

STEP 3

Your solution
We’ll return with your newly designed internal box liners and ask you to re-pack your perishable items, including our thermal temperature gauge. You send this back to us, and we monitor the temperature throughout the delivery process.
Detail of Dufaylite Design Lab Ultra Board bespoke solution

STEP 4

Findings
Finally, we’ll re-visit you with a detailed report outlining the findings of our temperature trial test. This assesses the performance of our eco friendly box liners working with your product.
Woman working out costings with a calculator

What you can expect from us…

Dufaylite Recycle Logo

Commitment to a greener future

We’re not just talking the talk – we’re walking the walk. Our eco friendly food packaging is crafted from 100% recycled and recyclable materials, so you can serve up sustainability with every delivery. Whether it’s chilled packaging or fresh products, together, we can make a big impact, one box at a time.

Dufaylite ideas icon

Tailored innovation

No two food businesses are alike, and we get that. Our design team thrives on creating bespoke packaging solutions that tick all your boxes – whether you need insulation for fresh goods or a reliable, sustainable food packaging option. Innovation is in our DNA, and we’re ready to bring that spark to your packaging.

Dufaylite made in the UK icon

Crafted in the UK, delivered with care

When it comes to quality, we don’t cut corners. Every single product, from biodegradable food packaging to insulated box liners, is crafted right here in the UK, ensuring the highest standards from start to finish. Plus, our service is as seamless as our packaging – no stress, no delays, just exceptional solutions delivered right when you need them.

Dufaylite sustainable icon

Expertise with a side of sustainability

With decades of experience under our belts, we can safely say, we know what we’re doing. By mastering the craft of sustainable food packaging, from thermal food boxes to honeycomb insulation, every solution we offer is designed with both your products and the planet in mind. So your goods stay fresh, your brand stays green, and your customers stay happy.

Dufaylite Bespoke Measurements Icon

Bespoke solutions, made for you

Your business is unique, and so are our packaging solutions. We specialise in creating tailored designs that perfectly fit your product’s needs, from custom sizes and insulation to branding that reflects your identity. Whether you need sustainable packaging for chilled goods or durable protection for fresh products, we’ll craft a solution that’s a seamless fit for your business.

Dufaylite building customer relationships icon

Collaboration at every step

Our process is built around partnership. From the very first conversation, we work closely with you to understand your challenges and goals, ensuring the solution we deliver is exactly what you need. By staying in constant collaboration, we make sure your packaging is not only sustainable but also perfectly aligned with your vision and values. We’re here to help you succeed – together.

Frequently Asked Questions

Ready to make the switch?

Contact Dufaylite today to explore how we can tailor our packaging solutions to meet your unique needs. Together, we’ll drive smarter, greener choices for your business.