REASONS TO BUY
Excellent seal
Convenient size
Durable design
Exterior pocket
Rubber feet
REASONS TO AVOID
Stiff latches
No dry basket included
Orca 40 Review
An impressive mid-sized model that offers high-quality insulation and simple but convenient features
Credit: Amazon
RELATED: Best Coolers of 2024
Our Verdict
Another impressive offering from a top brand, the Orca 40 is an excellent medium-capacity cooler. Its 40-quart volume is exceptionally useful, while sturdy construction in all the places that count, like the hinge, seal, and latches, lends confidence to its longevity. Though it doesn't come with an internal dry basket, we love the external mesh pocket that handily stores plates, spices, and utensils to accompany picnics and camping trips. It's one of the very few models we tested that's actually airtight, with a welded seam joining the two ends of its rubber seal, adding to an impressive insulation performance for its size. That said, this unit landed in the middle of the pack in terms of insulation.
Editors Note: This review of the Orca 40 was edited for clarity on May 20, 2024.
Compare to Similar Products
 This Product
Orca 40 | |||||
|---|---|---|---|---|---|
| Awards |  Best Wheeled Cooler | If You Need More Space |  Best Wheeled Cooler on a Budget | Best Traditional Cooler on a Budget | |
| Price | $325.00 at Dick's Sporting Goods Compare at 2 sellers | $400.00 at REI Compare at 3 sellers | $360 List $359.95 at Amazon | $227 List $239.95 at Amazon | $230 List $229.95 at Amazon |
Overall Score  |
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| Star Rating | |||||
| Bottom Line | A durable mid-sized option that stands out from the crowd, offering simplicity, convenience, and impressive insulation | While on the pricier side, you can't beat this cooler's insulation | Top-notch insulation in a long-lasting, compact design that will last for years to come | A durable but heavy wheeled cooler with high-end build quality and convenient features | With reliable performance, this cooler is a great shape, easy to use, and a good value |
| Rating Categories | Orca 40 | Yeti Roadie 48 | ORCA 58 Quart | Xspec 45 Towable | Xspec 60qt |
| Insulation (50%) | |||||
| Durability (20%) | |||||
| Ease of Use (15%) | |||||
| Portability (10%) | |||||
| Additional Features (5%) | |||||
| Specs | Orca 40 | Yeti Roadie 48 | ORCA 58 Quart | Xspec 45 Towable | Xspec 60qt |
| Shelf Life of Food (Measured Days Below 40ºF) | 5.0 | 6.8 | 6.7 | 5.9 | 6.1 |
| Days of Cold Beverages (Measured Days Below 50º F) | 5.5 | 7.5 | 7.3 | 6.4 | 6.7 |
| Measured Weight | 26.6 Ibs | 26.6 Ibs | 30.5 Ibs | 34.9 lbs | 30.3 Ibs |
| Measured Capacity in Cans | 53 | 77 | 82 | 69 | 90 |
| Measured Capacity | 37 qt | 45 qt | 56 qt | 48.7 qt | 57 qt |
| Advertised Capacity | 40 qt | 48 qt | 58 qt | 45 qt | 60 qt |
| Measured Internal Maximum Body Height | 11.3" | 15.8" | 13.0" | 16.1" | 13.0" |
| Does it Fit a Wine or 2L Bottle Standing Upright? | No | Yes | Yes | Yes | Yes |
| Measured Exterior Dimensions (L x W x H) | 25.6" x 18..4" x 17.0" | 20.1" x 19.8" x 20.8" | 26.6" x 20.0" x 19.4" | 23.2" x 19.2" W x 21.0" | 29.5" x 17.0" x 18.0" |
| Drain Plugs | 2 | 1 | 0 | 1 | 1 |
| Outer Construction | Rotomolded | Not listed | Rotomolded | Rotomolded | Rotomolded |
| Inner Construction | Not listed | Pressure-injected polyurethane | Manufacturer lists 'Extra-thick foam-insulated walls & insulated lid' |
Manufacturer lists '3" roto-molded insulation' |
Manufacturer lists 'Integrated insulation' |
| Warranty | 5 Years | 5 Years | 3 Years | 30 Day Return Policy Only | 1 Year - Limited |
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Our Analysis and Test Results
The Orca 40 is a rotomolded cooler with indented hard plastic, foam-covered webbing handles, and an internal height of 11.25 inches — not quite tall enough to accommodate most upright bottles of wine or 2L bottles. It features a dual-size drain, tie-down loops, a mesh pocket on the back, and certification from the IGBC.
Performance Comparison
The Orca 40's lid stays open, so you won't have to worry about it shutting on you while loading up.
Credit: Abriah Wofford
Insulation
Though Orca's vague claim that the Orca 40 maintains the “freshness of your stowed items for up to 10 days” leaves room for interpretation, this small model performed well for its size during our insulation testing. In our insulation test, the Orca 40 lasted five days, maintaining sub 40°F temperatures, the recommended threshold to maintain the freshness of the most sensitive food items, including raw meat and dairy. This 40-quart model kept internal temps below 50°F for several more hours, lasting 5.5 days in our hot room below that threshold.
The logged temperature of each cooler in our lineup.
Credit: Genaveve Bradshaw
While the Orca 40 is great for a long weekend trip, there are other compact options that will last a bit longer, as shown in the graph below.
The graph above shows the logged internal temperature increase of our midsize coolers over the course of nine days.
Credit: Genaveve Bradshaw
Durability
As we've come to expect from rotomolded coolers, the Orca 40 feels solid and well-built. Its rubber latches (shaped like orca tails) are some of the thickest and least flexible we've laid our hands on, adding to our confidence in their ability to withstand the test of time better than many others. Both sets of handles proved to be more than adequate enough to haul around this cooler filled with drinks and road trip snacks. Even the mesh pocket on the back is attached well and never caused any issues or gave us any worry during our testing period.
We had no issues with the drain plug, nor did we see anything that makes us worry about it eventually leaking. The integrated hinge for the lid is robust and gave only the smallest noise of complaint when we attempted to overextend it. As an IGBC certified product, this cooler proves itself very well-suited to withstand an impressive amount of use and abuse — we sat, stood, and jumped on it. Barring extraordinary abuse or circumstances, we expect this cooler to last a very long time.
The Orca 40 is IGBC certified and durable, with attention given to every detail that not all of its competitors can boast.
Credit: Maggie Nichols
Ease of Use
As a mid-sized model, the Orca 40 is fairly simple and straightforward, making it easy to use. The lid stays open at 90 degrees for easy loading, while the top is textured, helping it better hold whatever you set on top of it. The drain plug has two size options for easy use; unthread it slightly, and a channel running through the plug lets water out, or remove the plug entirely for faster drainage. Like most models we tested, it lacks a leash connecting the plug to the body of the cooler, so be certain not to misplace your cap. The exterior mesh pocket is sealed by a wide strip of velcro to make sure whatever you put in it stays.
The drain plug can be fully removed for quicker drainage, or partially unthreaded for a slower rate of drainage.
Credit: Maggie Nichols
Portability
The Orca 40 weighs just over 26 pounds. Filled to the brim with delicious refreshments, it's not a lightweight item to cart around. Curved, rubber-covered webbing handles make for fairly easy two-person carry, while indented handles under the sides of the lid provide useful single-person grips. Its narrow profile adds a bit to the comfort of carrying this medium ice chest despite its slightly taller shape that can bump against knees at times. Rubber feet help it to stay in place in the trunk of your car or deck of your boat while in use. Overall, it doesn't have any standout features that make it comparably easier or harder to carry.
The narrow profile and mid-sized, 40 quart volume make the Orca a reasonably easy chest to carry to a beach rendezvous.
Credit: Maggie Nichols
Additional Features
While a relatively simple cooler, the Orca 40 has several understated features that we love. To accompany tie-down slots on either side of the unit are indented channels on the edges of the lid that help to hold your strap in place, even as you bounce over uneven terrain. Thick rubber feet underneath further add to this stability. The front corners of the lid have lockable sections if you need to keep your food safe from roaming bears. As mentioned, we love the large mesh pocket on the backside of the cooler. We continuously found it more useful than expected throughout testing for a slew of dry items, as it became a feature we missed on other coolers without it. And if you feel you want more accessories and add-ons, Orca makes plenty of other options we didn't test with our standard model.
We love this unique mesh pocket and find it incredibly useful for holding extra necessities like bottle openers, napkins, and utensils.
Credit: Maggie Nichols
Should You Buy the Orca 40?
If you only need a cooler a couple of times a year, it might be overkill, but if you're searching for a mid-sized, 40-quart cooler that needs to withstand frequent use (and maybe abuse), we think the investment here is worth it. Its insulation is just about average, though it should be enough for most outings and camp trips.
What Other Coolers Should You Consider?
The Ultralight RTIC 52 is a great option in the medium-large size range. It's lightweight and easy to move around. Plus, it does well in its insulation performance. If you like the sound of the Orca but want it to be larger, you're in luck. The Orca 58 is one of our favorite coolers in the lineup. This lasted the longest in our insulation tests and has many of the same great features as the 40, like a mesh net.
We are very impressed with the construction, durability, and performance of the Orca 40.
Credit: Maggie Nichols
—
Genaveve Bradshaw, Maggie Nichols, and Rebecca Glades
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