Ethan Clarke
Plastic coolers are used for a variety of purposes, including picnics, hunting, camping, tailgating, and barbecues. They are made from different types of plastics and polymers, such as polyethylene, polypropylene, and polyurethane foam. The type of plastic used depends on the intended use of the cooler, with some plastics being more effective at retaining ice and insulation than others. Plastic coolers have evolved over time, with modern coolers offering improved ice retention and durability compared to earlier models. The manufacturing processes have also advanced, with rotational molding or rotomolding becoming the gold standard, creating seamless, sturdy, and long-lasting coolers. However, the environmental impact of plastic coolers, particularly the long-lasting properties of certain polymers, has become a growing concern.
| Characteristics | Values |
|---|---|
| Plastic type | Polyethylene, Polyurethane, Polypropylene, Polyvinyl chloride, Polycarbonate, Polyethylene terephthalate |
| Common uses | Food and beverage storage, medical and pharmaceutical applications, industrial and manufacturing processes, construction and building materials, packaging and containers |
| Benefits | Durability, impact resistance, flexibility, lightweight, moisture resistance, chemical resistance, electrical insulation, low price |
| Drawbacks | Environmental impact, difficult to recycle, potential leaching of chemicals |
| Manufacturing methods | Injection molding, blow molding, rotational molding or "rotomolding" |
| Insulation | Polyurethane foam, polystyrene foam, air-filled plastics |
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What You'll Learn
Plastic cooler insulation
Plastic coolers are made from a variety of materials, including vinyl, cotton, polyester, canvas, neoprene, nylon, and different types of plastics. The type of plastic used for a cooler depends on its use case. For instance, a soft cooler made of nylon or vinyl is suitable for daily use, while a metal cooler is ideal for semi-permanent fixtures. For hunting or camping, polyethylene rotomolded coolers are recommended.
The insulation used in plastic coolers is typically foam, with cheaper options using styrofoam and premium coolers using polyurethane foam. Polyurethane foam is denser than styrofoam, contains more and smaller air bubbles, and is harder, making it more durable and better at insulation. Polyurethane foam is also known as PU foam, which is produced from the chemical reaction between an isocyanate and a polyol, both of which are derived from crude oil. The hardness of the foam depends on the molecular weight of the polyol used.
While PU foam is extremely resilient and contributes to the longevity of the product, it has a negative impact on the environment. Its long-lasting nature makes it problematic when it ends up in landfills, and the extraction and production processes also contribute to environmental issues. Therefore, recycling PU foam is crucial to reducing its environmental impact.
To enhance the insulation of a cooler, one can add insulation to the walls and lid using polystyrene or styrofoam boards, which can be cut to size and glued in place. Filling in the gaps with duct tape or silicone and painting the interior with flex seal further improves insulation. Additionally, using a food-safe vinyl or plastic liner makes the cooler leak-proof and food-safe. These simple modifications can significantly improve a cooler's ice retention capabilities.
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Plastic cooler manufacturing
Plastic coolers are made from a variety of materials, depending on their intended use. For example, a soft cooler used for a daily lunch can be made from nylon or vinyl, while a semi-permanent fixture in a garage or backyard might be made from metal. Polyethylene is a common material used in plastic coolers, specifically high-density polyethylene (HDPE) for the exterior shell. Polyethylene is the most produced plastic in the world and has excellent electrical insulation and chemical resistance, as well as being low-priced and tough.
Other types of polyethylene include linear low-density polyethylene (LLDPE) and low-density polyethylene (LDPE). The raw material for HDPE is petroleum, with 1.75 kilograms of petroleum required to make 1 kilogram of HDPE. Injection-molded and rotomolded coolers are highly durable and can be used for professional purposes, hunting, and other challenging jobs. Rotational molding, or rotomolding, is considered the gold standard in cooler manufacturing, creating a seamless, one-piece construction. This process is also used to make river kayaks and other plastic equipment where structural integrity is vital.
Coolers are also commonly made from polyurethane foam, which is produced from the chemical reaction between an isocyanate and a polyol, both of which are derived from crude oil. The hardness of the foam depends on the amount of molecular weight of the polyol used. Polyurethane foam is extremely resilient and long-lasting, but it is harmful to the environment if it ends up in a landfill. Grizzly Coolers, for example, use polyurethane foam from EcoMate, which has superior thermal performance and durability.
Other materials used in plastic cooler manufacturing include polypropylene, high-impact polystyrene, and ABS. The choice of material depends on the intended use of the cooler, with some materials being more effective at retaining ice and cold temperatures than others.
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Plastic cooler environmental impact
Plastic coolers are typically made from polyurethane (PU) foam, polyethylene, and elastomer. While these materials have their advantages, such as durability, lightweight, and low price, they also have a significant environmental impact.
The production of PU foam, for example, involves the use of crude oil derivatives, isocyanates, and polyols, which can react to form a medium-density foam. This foam is highly durable and resilient, but its longevity becomes an issue when it ends up in landfills, contributing to environmental damage. The extraction and production of PU foam, as well as the transportation of raw materials and waste, contribute to environmental issues.
Polyethylene, the most produced plastic globally, is composed of carbon and hydrogen and offers advantages such as excellent electrical insulation, chemical resistance, and toughness. However, the production of polyethylene relies on petroleum, further contributing to environmental concerns.
Elastomer, another polymer used in plastic coolers, is derived from natural rubber trees. The excessive consumption of these trees for elastomer production can lead to ecological instability and increased carbon dioxide emissions during processing and transportation.
To mitigate the environmental impact of plastic coolers, some companies are taking initiatives to incorporate recycled materials into their products. For instance, Igloo's ECOCOOL collection uses recycled resin made from discarded plastic yogurt cups and milk jugs, reducing waste and promoting sustainability. Other companies, like Coolmax, also emphasize the use of recycled materials, water efficiency, and low energy consumption in their plastic coolers, contributing to a more eco-friendly approach.
While plastic coolers have their environmental challenges, some of their characteristics can be advantageous. Plastic coolers are lightweight, inexpensive, and safer to handle than metal alternatives. They are also weather-resistant and less likely to conduct electricity, making them a popular choice for cooling solutions.
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Plastic cooler uses
Plastic coolers are used for a variety of purposes, from picnics to vacations and holidays. They are also used to transport cold groceries home from the store, especially during hot summers, to prevent items like ice cream from melting. Some coolers even have built-in cupholders in the lid.
Plastic coolers are typically made with interior and exterior shells of plastic, with a hard foam in between. The foam is usually made from polyurethane (PU) or polyethylene. The latter is the most produced plastic globally and has a simple basic structure composed of only carbon and hydrogen. It is also tough, has excellent electrical insulation and chemical resistance, and is low-priced.
The type of plastic cooler one chooses depends on how it will be used. For instance, a soft cooler made of nylon or vinyl is suitable for daily use, such as carrying a packed lunch. A semi-permanent fixture, such as a cooler kept in a garage or backyard, might be made of metal. For hunting or camping, a polyethylene rotomolded cooler is a good option.
Rotationally molded (roto-molded) coolers have become popular in recent years. They are manufactured using a process called rotational molding, where a heated and softened material is applied to the inner wall of a slowly rotating mold. The mold continues to rotate during the cooling phase, producing a thick and uniform final product. Roto-molded coolers are durable and effective at retaining ice. Injection-molded coolers, on the other hand, use less plastic and are lighter, but may be less durable.
Plastic coolers are also available in the form of backpacks, which are lightweight and convenient for carrying goods over long distances or during travel.
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Plastic cooler alternatives
Plastic coolers are typically made from polyurethane (PU) foam, polyethylene, polypropylene, or poly styrene. However, due to the durability of the polymers used in plastic coolers, they can be harmful to the environment. Therefore, consumers may want to consider some plastic cooler alternatives.
Soft-sided coolers are a good alternative to plastic coolers and can be made from vinyl, cotton, polyester, canvas, neoprene, nylon, and more. These coolers are widely used and familiar to consumers. They are affordable, durable, and provide decent insulation and ice retention. Soft-sided coolers are also available in backpack form, which is a lightweight option that is perfect for those on the go.
For those looking for a more permanent solution, metal coolers are a great alternative. They are perfect for those who want a semi-permanent fixture in their garage or backyard.
Another alternative to plastic coolers is the Oyster Tempo, which uses double-walled vacuum insulation to keep food and drinks cold. The Tempo has an aluminum body that is compact and spacious.
Some other plastic cooler alternatives include the Canyon Outfitter 55 V2, which is constructed from rotomolded kayak plastic, and the Marine Ultra 70, which features excellent handles.
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Frequently asked questions
Plastic coolers are made from a variety of materials, including vinyl, cotton, polyester, canvas, neoprene, nylon, polyethylene, and polyurethane foam.
The most common type of plastic cooler is the hard plastic cooler, which is affordable, durable, and effective at insulation and ice retention.
Soft-sided coolers are often made from nylon, cotton-twill, heavy-duty vinyl, canvas, or other fabrics. They are generally more lightweight and portable than hard plastic coolers, and they can still keep goods cold for days.
