Maintaining stable temperatures during transit helps protect sensitive goods. Pharmaceuticals, biologics, food, beverages and other products can spoil if exposed to improper conditions. With the right number of gel packs, you can keep products at the correct temperatures during transit and last-mile delivery. Miscalculations could cause waste or result in extra costs, so it’s important to know how to incorporate gel packs into your cold chain shipping.
Challenges of Cold Chain Shipping
Cold chain items like vaccines, meat and other perishable items must remain within a specific temperature window to preserve their safety or efficacy. Even short, unrefrigerated trips can create unstable shipments, and exposure to poor conditions can result in added costs.
Temperature changes can even increase the risk of product contamination or spoilage. Cold chain breaches might break down ingredients, reduce shelf life or increase the risk of microbial growth. Shippers must find ways to keep products cold — even amid route delays and transportation surprises.
What Are Gel Packs, Cold Packs and Ice Packs for Shipping?
Gel, ice and cold packs are interchangeable terms for water-based gels contained in plastic pouches that prevent temperature excursions. They remove and absorb ambient heat during shipping, keeping products cold without undergoing drastic temperature changes. Thanks to their flexible, water-based design, you can mold gel units to fit your product during shipping.
Key Factors That Determine Gel Pack Quantity
Every cold chain shipment is different — the product, travel duration and packing style can all influence cooling needs. Keep these factors in mind to find the right gel pack quantity for the job.
1. Product Type and Temperature Sensitivity
The more sensitive the product, the better the thermal performance needed. Animal products, diagnostic samples and pharmaceuticals often have strict temperature requirements. Any error could mean the entire shipment is wasted. That sensitivity typically requires a larger thermal buffer. The edges of packages are especially susceptible to temperature excursions.
Perishables like produce have wider tolerances but still require monitoring. Match your gel pack quantity to the temperature demands of your shipments.
2. Packaging Volume and Insulation Quality
Packaging and insulation also affect gel pack cooling. Better insulation means the temperature remains more stable. Poorly insulated packaging might need additional cold packs to offset heat gain. More products and packaging also increase cooling needs. With greater volume, extra cooling power is necessary to protect products.
3. Transit Duration and External Temperature Conditions
The longer packages sit in transit, the greater the risk of temperature excursions. Last-mile deliveries may require minimal cooling, while multiday routes and warm weather typically demand more cold packs. Another consideration is whether the truck is refrigerated. Refrigerated trucks require fewer gel packs.
Best Practices for Using Gel Packs in Your Supply Chain
Once you’ve got your gel packs, you need to use them effectively. Poor ice pack management could lead to extra expenses, wasted product and additional logistic demands. Here are the four best practices for using pel packs to protect sensitive shipments.
1. Choosing the Right Size and Type
Cold packs for shipping food or other sensitive items use a water-based gel that’s flexible when refrigerated. You can shape them to fit your shipment and packaging and enjoy longer, better cooling. There are many types of gel packs available, including:
- Compostable gel packs: Compostable ice packs are easy to dispose of and eco-friendly. You or the end user can simply throw them in the trash, where they’ll gradually decompose.
- Drain-safe gel packs: These packs divert the water-based gel away from landfills, reducing the impact on greenhouse gas emissions.
- Cost-effective gel packs: These everyday refrigerants resist puncturing and deliver long-lasting cooling.
While dry ice is a common cooling solution, it can pose a safety hazard for refrigerated products. Gel packs are safer to handle and nonhazardous, so you avoid Class 9 regulatory constraints for hazardous shipping that apply to dry ice.
2. Pre-Conditioning Gel Packs
Gel packs are only effective if they’re prepared properly. Your operation should freeze or refrigerate gel units thoroughly before using them. Each pack must reach a specific temperature to cool as intended. Insufficient preparation can lead to shorter cold periods and uneven cooling. Water-based gel packs are easy to refrigerate or freeze and store in commercial spaces.
3. Proper Placement in Shipping
Throwing gel packs on top of boxes is inefficient. You need strategic cooling placement to optimize your temperature control. Make sure gel packs surround the product on multiple sides to create a refrigerated zone. Leaving one side exposed or stacking everything on top leads to uneven temperatures.
Also, ensure teams place a physical buffer between the gel inserts and the products to prevent accidental freezing due to direct contact. Physical barriers help achieve a balance.
4. Careful Monitoring and Validation for Quality Assurance
If you’re in cold chain shipping, you need data. Using gel packs is only effective if you’re testing them. Shipments might be thawing early or becoming too cold. Use test shipments and digital temperature loggers to see the shipment temperature throughout the trip. You’ll be able to spot risks, correct temperature issues and show end users your cooling quality for all shipments.
About Pelton Shepherd Industries: Leaders in Gel Packs for Shipping
Pelton Shepherd is more than a gel pack provider. We’re your partner in fine-tuning your cold chain solutions. For more than 70 years, we’ve supported temperature-sensitive shipments across the pharma, food and pet health industries. Brands like HelloFresh, Optum and Baxter trust our products to maintain cold chain integrity at scale.
We work directly with your packaging engineers and operations team to develop solutions specific to your needs. Whether you’re looking for a new refrigeration solution or you want to scale your program to address new growth, we can help. We can also store your refrigerants for you with our COLD (Conditioning Operations, Logistics and Delivery) Program.
Ensuring Safe and Compliant Cold Chain Shipments
Choosing the right number of gel packs doesn’t require guesswork — it necessitates a calculated strategy based on product, shipping and regulatory demands. With the right partner, you can ship confidently and sustainably.
Pelton Shepherd Industries is here to provide successful, cost-effective cold chain solutions that fit your unique products. As a third-generation family-run business, we have the experience to meet your needs and offer a personal touch that goes above and beyond basic service. Request a quote online to see how we can help protect your products during shipment.
