Most coolers are blow molded with an extremely thin layer of cheap plastic. Our coolers are constructed by rotational molding. The roto-molded process is a high temperature, low pressure, forming process that utilizes heat and dual axle rotation. While it’s a more time intensive process, the end result is a durable, one-piece part with no seams for maximum durability and life.
We use a minimum of 1/8 inch of UV stabilized polyethylene in the inner and outer walls for a total of over a 1/4 inch of durable, insulating plastic. This is the same material used in kayaks, and hockey rink walls. It has a high tensile strength, which gives it superior impact and puncture resistance compared to traditional coolers. Polyethylene is also the material of choice for most greenhouses due to its superior insulating capabilities per mil versus other plastics.
In between the walls and lid of every K2 cooler is up to 3 inches of K2’s premium grade high density polyurethane foam. Our 20 Quart has up to 2 inches of insulation which increases portability while still providing excellent ice retention. This foam creates millions of “pockets” to reduce heat transfer. While some may say we’ve gone overboard with the amount of insulation we put it in our coolers, we know it’s this foam that helps give K2 it’s incredible ice holding capabilities. The high density foam also gives our cooler walls and lids incredible strength and rigidity. You don’t have to worry about standing on one of our coolers! We also use an anti-delaminating grip that insures the walls and the insulation don’t delaminate, further extending the useful life of your cooler.
Each cooler then goes through a multi-step finishing process where the quality components below are installed. Our coolers are than subjected to a rigorous QC check before the K2 label is put on.
Roto molded, one-piece construction