Sustainability of Aluminium-Based Thermal Pallet Covers: A Leader’s Perspective

As the largest seller of aluminium foil and insulation-based thermal pallet covers in India, with a 25-30% market share, Mettcover India has been protecting temperature-sensitive shipments for over a decade. In an era where sustainability is a core business imperative, our aluminium-based thermal pallet covers stand out for their environmental performance. This blog examines their sustainability profile, focusing on the insulation materials we use: woven and non-woven fabrics, LDPE air bubbles (8 mm, 4 mm, and 20 mm thickness), and 20 mm polyester fiber fills.

What Are Aluminium-Based Thermal Pallet Covers?

Our thermal pallet covers are multi-layer protective blankets designed for air cargo and road shipments. Key components include:

• Outer and Inner Layers: High-purity aluminium foil (99.5% aluminium, 7-12 microns thick) for maximum radiant heat reflection.
• Core Insulation: Bonded to one or more of the following:
  • Woven and non-woven fabrics for structural strength and flexibility.
  • LDPE air bubbles (8 mm, 4 mm, or 20 mm thickness) for air-trapping thermal resistance.
  • 20 mm polyester fiber fills for additional insulation and cushioning.
• Construction: Heat-laminated for durability, with vapour barriers to prevent condensation.

These thermal covers shield pallets from solar radiation, ambient extremes, and tarmac delays, extending payload stability (e.g., 15-25°C ) by 6-8 hours in +40°C conditions without active cooling.

Sustainability Advantages

Our aluminium thermal pallet covers deliver strong lifecycle sustainability by minimising waste, energy use, and emissions in cold chain logistics.

1. High Recyclability and Low Waste:
   • Aluminium foil is 100% recyclable without quality loss, with global recycling rates of 75% (International Aluminium Institute, 2024). In India, recovery rates are 65-70% through informal and formal channels.
   • LDPE air bubbles and polyester fiber fills are recyclable (LDPE at 80-90% in organised sectors; polyester fiber can be reprocessed into new insulation).
   • Reusability: 50+ cycles with proper care, reducing single-use waste by 80% compared to disposable alternatives (internal lifecycle testing, 2024-2025).
2. Energy Efficiency and Carbon Footprint Reduction:
   • Double-sided aluminium foil reflects 95-97% of solar radiation (ASTM E903), cutting heat gain by 91-94% during tarmac exposure (Mumbai July 2025 tests: 1050 W/m² solar load, 4 hours).
   • Insulation layers (air bubbles + polyester fiber) provide thermal resistance (R-value ≈ 2.0-2.5 m²K/W) with low embodied energy.
   • Lifecycle CO2 emissions: 2-3 kg CO2-eq per cover over 50 cycles, vs. 5-7 kg for single-use options (ISO 14040 LCA standard).
   • In India, where 40% of pharma shipments face excursions (Pharma Export Promotion Council, 2024), these covers reduce re-shipment energy by 15-20%.
3. Resource Conservation:
   • Aluminium production uses bauxite, but recycled foil requires 95% less energy (Aluminium Association, 2024). Our covers incorporate 30-50% recycled aluminium.
   • Lightweight design (2-5 kg/cover) lowers fuel consumption in air freight by 10-15% (IATA fuel efficiency guidelines).
4. Compliance with Sustainability Standards:
   • RoDTEP-eligible (HSN 7607 for aluminium foil and 3921 for insulation), supporting Make in India with 0.3-3.9% rebates.

Aligns with EU CBAM (Carbon Border Adjustment Mechanism) by lowering embodied carbon (2-3 tCO2/tonne vs. 8-10 for steel alternatives).

Potential Drawbacks

For balance:

• Recycling Challenges: In India, informal recycling can lead to a 20-30% loss; formal channels are needed for full recovery.
• Energy-Intensive Production: Initial aluminium smelting has high emissions (16 tCO2/tonne), though recycled content mitigates this.
• End-of-Life Management: LDPE and polyester require proper disposal.

 Why Aluminium-Based Covers Are a Sustainable Choice

In India’s cold chain market (INR 8,500 crore in 2024, 12-13% CAGR), aluminium-based covers offer a practical path to sustainability: high recyclability, energy savings, and reduced waste. At Mettcover, with our 25-30% market share, we continue to innovate greener solutions—our latest double-sided foil designs cut emissions by 40% over cycles.

For more on how these covers can enhance your pharma air cargo sustainability, connect with us @info@mettcoverglobal.com

References: International Aluminium Institute (2024), DuPont LCA (2023), Pharma Export Promotion Council (2024), IATA TCR (2025).

To know more, read here: The Science Behind Insulaite Thermal Pallet Covers