Shrink Wrapping Styrofoam Coolers with Polypack: A Proven, Scalable Solution

Looking to Automate Cooler Shrink Wrapping for High-Volume Production?

Many food, beverage, and fulfillment operations use styrofoam coolers to protect temperature-sensitive products, from BBQ meals to seafood, meal kits, and medical supplies. As demand grows, manual wrapping quickly becomes slow, inconsistent, and labor-intensive.

That’s where a Polypack shrink-wrapping system can make a measurable difference. Designed for high throughput and precision handling, Polypack machines deliver clean, tight, protective wraps, even on lightweight, heat-sensitive materials like EPS foam.

When Corky’s BBQ needed an automated solution to package large volumes of styrofoam coolers, Polypack engineered a Polypack IL shrink wrapper to streamline their entire process.

Designed for Reliable, Repeatable Performance

Styrofoam coolers can be difficult to handle, but Polypack’s approach combines smooth product control, balanced airflow, and precision sealing to ensure each unit is wrapped securely and consistently.

1. Automated Infeed and Product Spacing

The infeed conveyor automatically receives products from upstream equipment and guides them through the film curtain with consistent spacing. This ensures steady, uninterrupted production and helps operators maintain efficiency across shifts.

2. Dual Film Feeds with Automatic Tension Control

Film is dispensed from upper and lower rolls using a dancer bar system that senses film demand and adjusts automatically. This maintains perfect film tension, eliminating wrinkles, tearing, or slack even during long production runs.

3. Consistent Sealing Every Time

At the heart of the system, a thermostatically controlled seal bar assembly creates a smooth, uniform seal and cut as each cooler passes through.A photoelectric sensor detects every product, triggering the seal precisely when needed. Temperature controls allow easy adjustment for different film types or product densities.

4. Smooth Transfer to the Shrink Tunnel

Once sealed, products move to the transfer conveyor, synchronized in speed with the tunnel conveyor to ensure gentle handling. The coolers stay perfectly aligned as they enter the shrink tunnel for final wrapping.

5. Precision Shrink Tunnel for Delicate Products

The shrink tunnel uses adjustable baffles and replaceable heater banks to deliver balanced, efficient heat. Air circulates evenly around the coolers, shrinking the film tightly without disturbing or overheating the foam.The result is a clean, professional wrap — ideal for distribution or retail presentation.

Let’s build Your Cooler Wrapping System

If you’re ready to automate cooler wrapping or scale up production, Polypack’s team can help you select the right system and configure it for your operation.

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