custom logo hard cooler boxes manufacturer

Wholesale Custom Cooler Boxes Manufacturer

As an experienced hard cooler manufacturer, we possess multiple production lines and comprehensive manufacturing capabilities to support your requirements. Our existing ice chest models are suitable for various application scenarios, from harsh outdoor survival situations to relaxed picnic and camping activities. We offer coolers that balance budget and performance. We focus on high-end rotational molded hard coolers, light-weight and low-cost blow molded ice chests, and multi-purpose injection molded ice cooler boxes to ensure a perfect balance between insulation efficiency, portability, and manufacturing costs. We provide fully customized services, including colors, sizes, private logos, and patterns, enabling us to transform your ideas and sketches into market-leading products.

hard cooler layered structure

Advanced Insulation Technology

Our coolers are constructed with a sturdy three-layered structure and sealing device: rugged plastic waterproof outer wall – PU/EPS insulation layer – food-grade safe plastic inner wall, a single or double plastic/stainless steel lock clip together with a 360° sealing ring. While ensuring sufficient wall thickness, they jointly block the exchange of hot and cold air both inside and outside, prevent deformation due to impacts, and guarantee a minimum cold preservation time of 48 hours (most blow molded coolers), and rotational molded ice chests can even achieve a cold preservation time of more than 5-7 days.

12QT Plastic Outdoor Camping Fresh-keeping Mini Portable Ice Chest Hard Cooler Box with Shoulder Strap 11L

Versatile Usage Scenarios

Our coolers are applicable to various occassions. The large-capacity, sturdy rotomolded coolers are suitable for extreme conditions or for long-term cold preservation need during severe field survivals. We also have injection-molded ice boxes with moderate capacity, which are suitable for lightweight outdoor activities such as fishing and camping. Some innovative mini coolers with small capacity, bright colors, and built-in shoulder straps, which are lightweight and portable, are suitable for weekend picnics and park walks.

ice chests practical design details

Practical Design Details

Our design team has over a hundred successful project experiences and understands the actual needs of the target users. They incorporate various practical details into the design to enhance the user experience and satisfaction. For example, anti-slip and shock-resistant base ensure that the contents will not be damaged due to excessive jolting during transportation; Heavy-duty wheels and sturdy handles to improve portability; Some lid models are designed with circular grooves to place bottles∪︀ Internal partitions to better organize the contents, etc.

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TIERED PRICING FOR BULK ORDERS!

Your Brand, Backed by Proven Excellence

Global Compliant & Quality Assured Cooler Boxes & Ice Chests

We are well aware that compliance is crucial for your entry into the market. Our factory has passed the BSCI audit, and all products are made from environmentally friendly materials that comply with FDA and LFGB standards. Whether your target market is North America, which values ultimate performance, or Europe, which emphasizes environmental safety, we can provide you with a complete compliance package, helping your brand smoothly pass through customs and win the trust of consumers.

Certification Focus Area Description
FDA / LFGB Food-Grade Safety Ensure that all lining materials are non-toxic and suitable for direct contact with food, which is of crucial importance for market access in Europe and the United States.
IGBC Bear-Resistant It can verify the structural integrity of the product under extreme physical forces in the wild, targeting the high-end outdoor market in North America.
RoHS / REACH Chemical Compliance Guarantees the product is free from hazardous substances and eco-friendly.
ISO 9001 Quality Management Demonstrates factory reliability and manufacturing maturity.
BSCI / SEDEX Social Responsibility Moral production audits covering labor rights and working conditions. A mandatory entry requirement for major retailers like Walmart, Target, and Costco.

High-Quality Hard Cooler Molding Techniques

Blow Molding

The principle of this process is to extrude molten plastic into a tubular shape, place it in the mold, and then use high-pressure air to “blow” the plastic towards the inner wall of the mold. It is similar to the process of inflating a balloon. The double-layer walls of the cooler produced by this method need to be assembled, so inevitably produces weak points at seam lines, but compared to injection molding, the box body is lighter, more portable, and has a shorter production cycle than injection/rotational molding. It offers better price advantages in large-scale orders. The market positioning is for family weekend camping, self-driving trips, mid-range retail markets, etc.

  • Ice retention: 12-48 hours
  • Relatively thin wall thickness
  • Moderate mold cost

Injection Molding

Melted plastic is injected into a precise metal mold under high pressure. After cooling, the plastic solidifies into the shape of the mold cavity. This process is often used to manufacture coolers with complex shapes, enabling multi-color assembly, intricate brand logo display (In-Mold Decoration), and high-precision component integration.

  • Moderate wall thickness

  • Ice retention: 3-5 days

  • High mold cost

  • Target market & application: Short-term picnics, parties, business gifts.

Rotational Molding/Rotomolding

Place the powdered plastic into the mold, heat it to a certain temperature to melt the plastic, and rotate it slowly in two axial directions to allow the molten plastic to evenly coat the inner wall of the mold under the influence of gravity. After cooling, it forms a seamless and integrated structure with uniform wall thickness. Especially at the corners subjected to the greatest force, the wall thickness is thicker than that of other processes. The structure of the finished product is extremely strong, and it is usually used to manufacture “bear-proof” type sturdy coolers. However, at the same time, it is also very heavy and difficult to move.

  • Thick wall thickness

  • Most prolonged Ice retention: 5-7 days

  • Low mold cost

  • High production cost

  • Target market & application: Off-road, exploration, deep-sea fishing, customizations for high-end outdoor brands.

Manufacturing Capabilities & Packaging Solutions

Looking For A Reliable Hard-Sided Cooler Manufacturer Factory To Support Your Brand?

KingStar offers one-stop manufacturing services, which can assist you in completing every stage of the hard cooler development. From the initial conception and design, the selection of molding techniques and materials, to prototype production, testing, and large-scale production, we will closely collaborate with you to transform your ideas into products that align with your brand positioning. Once the design is finalized, we will seamlessly transition to large-scale production to ensure that every ice chest has precise consistency. Additionally, we are responsible for global logistics management to ensure that your products can be safely and efficiently delivered to any location that needs them around the world. If you have any questions or want to discuss your project, please contact us through our online messaging system or send an email to sales@waterbottle.tech. We guarantee to respond within 24 hours.

Your Custom-Designed Plastic Hard-Sided Ice Chest Manufacturer Factory

Custom Hard Cooler Mold Tooling Process

Step 1: Sign NDA

NDA is the abbreviation of Non-Disclosure Agreement. Before you disclose any confidential information (such as drawing or design concepts) about your custom water bottle project, we sign NDA with you.

Step 2: Complete Design Drawing

Base your drawing, our engineering team will release DFM (Design For Manufacturing) report and help revise the drawing. If you only have a design concept without drawings, our R&D team offers design support to complete the drawing.

Step 3: Quotation & Payment

After having all your requirement, we quote for both tooling cost and product pricing. Payment term for tooling is that, 50% deposit and 50% after sample approved by you. Payment term for mass production is normally 30% deposit + 70% balance before shipment.

Step 4: Tooling Fabrication & Sample Approval

Lead time of tooling fabrication is 5 weeks. You will get a 3D printed prototype sample to finalize the design, and T1, T2 samples for final approval on your custom mold design bottle tumblers.

Step 5: Mass Production

After T2 tooling sample is approved and deposit payment received, we then start mass production. The lead time of mass production is 45 days. It’ll be even longer for custom design smart water bottle projects.

Step 6: Final Payment & Shipping

After receiving final payment, we will work with your forwarder to arrange the shipment. If you have no experience in importing from China, we can handle the whole logistics and arrange globally door-to-door shipping.

FAQs About Wholesale Plastic Insulated Hard Cooler Boxes

We’ve compiled a list of the most frequently asked questions to make it easier for you to find the information you need. Whether you’re looking for details about our wholesale blank bottles or custom beverage containers, you can quickly access helpful answers here.

  1. General outdoor adventures

For enthusiasts who enjoy off-road driving and long-term camping, our rotomolded cooler boxes can be used to retain low temperature for 5 to 10 days. Their sturdy construction also enables them to serve as a stepping stool, seat, or tabletop in the wild.

  1. Fishing and other water activities

Our cooler shells have been specially treated to have UV protection. Some models even come with anti-slip foot pads. Even when exposed to direct sunlight, they can maintain the freshness of fish and seafood, and have the resistance to seawater corrosion, and thus are perfect for use on the deck.

  1. Cold chain logistics

In cases where vaccines, biological samples, or high-end perishable or deteriorating goods that require strict temperature control are transported over short or long distances, some vehicles or shipping devices do not have sufficient power sockets to supply electricity to refrigerators. This passive cooler, combined with ice packs and dry ice, can perform the task excellently without requiring any power connection.

  1. Hunting

The large-capacity and sturdy cooler can be used for storing the meat after hunting. The pre-cooled cooler with ice blocks inside can be used for quickly cooling fresh meat. Combined with the easy-to-operate drainage valve, the melted water can be promptly discharged.

  1. Humanitarian aid and disaster relief

These hard coolers become essential basic facilities for storing food and water needed by emergency rescue workers and disaster victims in places without a steady power supply, particularly during the summer or at low latitudes.

A high-quality hard cooler is a long-term value investment with a lifespan of over ten years. Correct maintenance not only keeps it in a brand-new appearance but also ensures that the silicone gaskets and insulation materials remain in optimal performance.

  1. Clean after each use

After each use, especially when after storing raw meat or fish, clean the interior with a mixture of mild detergent and warm water. For stubborn odors, you can use a solution made of water and baking soda, or a mild bleach and water ratio (1:10). Do not use rough scrubbers or irritating industrial chemicals as they may damage the food-grade lining material.

  1. Drainage plug and gasket

The freezer-grade gasket is the key component for maintaining the sealing effect.

  • Check for debris: Ensure that the groove of the sealing gasket strip is free of sand or dust, as these debris can cause air leakage, and foreign substances remaining in the gasket for a long time may cause it to deform and affect the sealing effect.
  • Lubrication maintenance: Occasionally(every 6 to 12 months) wipe the gasket with a silicone-based protective agent to keep the rubber soft and prevent it from cracking over time.
  1. Storage

Although our cooler features UV protection, prolonged and unnecessary direct sunlight exposure may still cause the outer wall to fade. Please store the cooler in a cool and dry place, such as a garage or basement.

  1. Latch and hinge inspection

After each use, it is necessary to regularly inspect the T-shaped lock and hinge pin. If any problems are found, they should be dealt with as soon as possible, such as applying lubricating oil or replacing them in time. If your cooler has come into contact with salt water, please thoroughly rinse these metal/rubber parts with clean water to prevent salt crystallization and premature wear.

We understand that brand-building takes time. We maintain a “Ready-to-Ship” inventory of neutral colors that allow for Low MOQ (Minimum Order Quantity) logo customization, enabling you to test the market without heavy upfront capital investment in thousands of units.

We adopt the tiered pricing, where the larger the production volume, the lower the unit cost. This is because for bulk orders, the fixed costs (machine calibration, color matching, and labor costs) can be spread over more products. For large importers, this significantly increases their retail profit margin. Of course, we also offer assistance to small or start-up businesses, providing lower minimum order quantities(MOQ) or trial orders, but the unit cost will be slightly higher.

We offer both simple customization and deep customization.

  • Simple customization: You can modify the color of any of our existing model (any Pantone color code), add logos (screen printing, heat transfer printing, embossed plates…), text and specific patterns, as well as unique surface treatments (mirror polishing, unique textures…), etc.
  • Deep customization (new mold required): This is a complete OEM/ODM process. During this process, we will create new molds to build specific capacities, unique shapes, or exclusive features that are specific to your brand. However, due to the high initial cost, you may need a larger quantity or a higher pricing to achieve certain profit margin.

Our different models of coolers may adopt different production techniques. All these three are included. If you want to know which manufacturing technique is adopted of a certain product model, please refer to the specifications table or detailed description on the specific product page. Rotational molding, injection molding and blow molding each have their own advantages and disadvantages. When customizing, you can consider your desired brand positioning and product performance requirements comprehensively to make a choice, or discuss with our engineers for recommendations.

  1. Rotational molding (rotomolding)

Rotational molding is the top industry-standard manufacturing technique for durability and ruggedness. Many high-end brands such as YETI use this technology for their hard coolers.

During the rotomolding process, a hollow mold is filled with plastic powder (usually low-density polyethylene) and then heated and rotated. The plastic melts at a certain temperature and evenly covers the inside of the mold (especially the corners) under the effect of centrifugal force. This process can directly produce the inner and outer double-layer walls of the cooler, which are formed as a single piece and seamlessly connected; while other technologies usually form the inner and outer walls separately and then assemble them together, thus there are weak points at the seams, making them more prone to damage and potentially affecting the insulation performance during collisions.

Main features: rugged construction, prolonged ice retention, low upfront mold costs; heavy in weight, high manufacturing costs

  1. Injection molding

Melted plastic at a high temperature is injected under high pressure into a metal mold that has been precisely machined. This enables the cooler to have greater design flexibility, such as complex shapes, internal partitioned walls, surface treatment methods (such as in-mold labeling or decoration), etc. Injection-molded coolers are usually lighter than rotomolded cooler boxes, but more durable than blow-molded ones, with manufacturing costs in between.

Advantages: Lightweight, high dimensional accuracy, excellent surface finish & thermal insulation performance; supports complex designs; moderate cost.

Disadvantages: High initial mold cost (increasing production can reduce the unit cost per product); slightly thin wall thickness

  1. Blow molding

Blow molding, as the name suggests, is the process of injecting molten plastic into a mold and forcing it to expand by air pressuring. Molten plastic is pushed into the mold and inflated. The high air pressure squeezes the plastic to change its shape until it matches the mold. This method results in thinner cooler walls but lighter in weight and lower manufacturing costs, mainly suitable for entry-level outdoor activities for the mass market.

Features: The most lightweight and portable, with the lowest production cost; Relatively thin wall thickness, and relatively short ice preservation time(usually 1-2 days).

Yes. For our standard model, samples can be dispatched within 3 to 5 working days. For simple customization requests (such as color customization, logo printing, etc.), the delivery period for samples is approximately 7 to 10 days; for complex customization requests requiring a new mold, the sample delivery period is longer, ranging from several weeks to several months. The sample cost is usually deducted in your first large-scale production order.

Yes. The majority of the hard-sided coolers we produce are made of food-grade LLDPE (linear low-density polyethylene), and all the different materials of our models do not contain bisphenol A. Our products comply with the food contact standards of FDA and LFGB, ensuring their ability to come into direct contact with dairy products, fish, meat and other perishable items, and guaranteeing their safety. In addition, our production facilities have also obtained ISO 9001 certification to ensure the consistency of quality control. In your order, we will include relevant certificates or third-party test reports.

Most of our high-performance ice chests use high-density polyurethane (PU) foam, which is pressed into the inner layer between two plastic walls. This creates a layer of insulation barrier, and its insulation effect is much better than that of the air gaps or EPS foam used in cheaper alternatives.

Unlike refrigerators that require the use of electricity to generate cold air and maintain low temperatures, a cooler is a passive heat insulation barrier that achieves its insulation effect by slowing down the transfer of external heat to the interior. It accomplishes this through the following three scientific principles:

  • Utilizing poor heat conductors to block heat transfer: Thick polyurethane (PU) foam is filled in the core of the cooler. Millions of tiny bubbles in this foam form a “heat barrier zone”.
  • Reflecting heat radiation: The outer shell is usually made of low-density polyethylene and is treated with UV protection on the surface, which can reflect solar radiation, preventing the surface of the cooler from heating up when exposed to sunlight.
  • Sealing: The inner part of the lid uses silicone rubber gaskets. By creating a sealing effect, this design prevents “convection” between the hot air outside the box and the cold air inside the box.

KingStar has built a reputation as a trusted partner in the OEM/ODM manufacturing industry by adhering to strict ethical standards and complying with international intellectual property laws. We fully understand the importance of protecting your unique designs, innovations, and business ideas, especially in a competitive industry like drinkware manufacturing. To provide peace of mind, we are more than willing to sign a Non-Disclosure Agreement (NDA) or a Non-Use, Non-Disclosure, Non-Circumvention Agreement (NNN) before you share any proprietary designs, sketches, or specifications with us.

When you collaborate with KingStar:

  • Confidentiality is our priority: Whether you’re a start-up or a well-established brand, we value your trust and ensure that your proprietary information remains secure.
  • Dedicated project management: From the moment you submit your design to the final production phase, a dedicated project manager oversees your project, ensuring that your intellectual property is treated with care and respect.
  • Data security: We utilize secure communication channels to share and store files, minimizing the risk of unauthorized access or leaks.

T/T 30% deposit after order signed and 70% against copy of B/L.
L/C at sight is acceptable too.

If you would like to get samples from us in order to test or make reviews, please contact our Sales / Branding department at sales@waterbottle.tech.

Normally It takes 4 weeks.

For existing model samples, it takes 2-3 working days. If you want samples with your own designs, it takes 5-7 days or even longer. Let’s discuss case by case.