Choosing the Right Large Gel Pack for Temperature-Sensitive Shipping
What is a large gel pack?
Large gel packs are gel packs with weights between 48-96oz. Large gel packs are perfect for companies that need to maintain refrigerated temperatures between 32F and 40F in larger boxes or containers with temperature sensitive products.
We’ve found that larger customers with standardized box sizes and packouts achieve longer cooling performance with larger gel packs, as their greater thermal mass retains cold more effectively than multiple smaller gel packs of the same combined weight. Additionally, appropriately sized boxes can be designed for optimal packing efficiency and reducing packing time
IPC manufactures gel packs at our headquarters in Los Angeles and our gel pack factory in Dallas, Texas, offering four key product lines to meet your gel pack needs:
Consumer Grade Gel Packs
Our consumer-grade cold packs feature clear safety labeling for worry-free use in every delivery.
Check out our Consumer Grade Gel Packs
Drain Friendly Gel Packs
Non-toxic and drain-friendly, our gel packs offer hassle-free disposal in running water, ideal for longer shipments and consumer deliveries.
Check out our Drain Friendly Gel Packs
Sweat Proof Gel Packs
Feature an advanced layered exterior to minimize condensation, keeping deliveries dry and intact.
Check out our Sweat Proof Gel Packs
Industrial Blue Gel Packs
Crafted from tough, recyclable polyethylene plastic, proven to resist punctures and tears even during the most rigorous handling.
Check out our Industrial Blue Gel PacksWe can manufacture custom sizes and custom print on gel packs contingent upon higher minimum order quantities.
Large Gel Packs Standard Size Table
| Weight | Dimensions* | Item Code | Quantity / Case | Weight / Case | Cases / Pallet |
| 6 oz | 4.5" x 5.5" | GT-6 | 96 | 36 | 50 |
| 8 oz | 4.5" x 6.25" | GT-8 | 72 | 36 | 50 |
| 12 oz | 4.5" x 7.5" | GT-12 | 48 | 36 | 50 |
| 12 oz | 6" x 7.5" | GT-12 NW | 48 | 36 | 48 |
| 15 oz | 4.5" x 7.5" | GT-15 | 48 | 36 | 50 |
| 16 oz | 4.5" x 8.5" | GT-16 | 36 | 36 | 50 |
| 16 oz | 6" x 8" | GT-16 6X8 | 36 | 36 | 50 |
| 24 oz | 4.5" x 10" | GEL-24 | 24 | 36 | 50 |
| 24 oz | 7″ x 8.5″ | GEL-24W | 24 | 36 | 50 |
| 24 oz | 6″ x 8″ | GT-24W13 | 24 | 36 | 50 |
| 24 oz | 7″ x 12″ | GT-24X12 | 24 | 36 | 50 |
| 32 oz | 6.5″ x 9″ | GT-32W | 18 | 36 | 50 |
| 48 oz | 7″ x 11" | GT-48 | 12 | 36 | 50 |
| 64 oz | 10″ x 11" | GT-64 | 10 | 36 | 50 |
| 64 oz | 10″ x 13″ | GT-64X13 | 10 | 36 | 50 |
| 80 oz | 10″ x 13″ | GT-80 | 8 | 36 | 50 |
| 96 oz | 10″ x 13″ | GT-96 | 8 | 36 | 50 |
How many gel packs do I need?
The general rule is to use 1 pound of gel for every 2 pounds of product. However, the exact amount will vary based on ambient temperature, payload density, transport time, and insulation effectiveness.
Large Gel Packs Use Cases
Pharmaceutical Shipping: Keeping Medication Safe
Large gel packs are useful for medical distributors or pharmaceutical companies sending bulk shipments of temperature sensitive medication, like shipping GLP-1 Injectables, in larger boxes to pharmacies using standard shipping rather than refrigerated trucks.
Grocery Delivery: Ensuring Freshness and Quality
As rural populations continue to stagnate or decline, cities will continue to grow into 2030. Urban consumers show a preference towards convenience and speed. Grocery delivery services, which includes meal kits, will experience a massive boom in the coming years with a 27% increase in revenue in 2025 alone. Large gel packs are an industry standard in the meal kit and subscription food delivery market.
FAQ about Large Gel Packs
How long do gel packs stay cold?
Gel packs can stay cold between 24-48 hours depending on how much gel you pack, ambient temperature and the insulating performance of your insulated box liner. A large gel pack or two with a curbside recyclable insulated box liner should be able to stay cold between 48-72 hours during summer(1).
Can large Gel Packs be Reused?
Large gel packs can be reused. Some companies with temperature-sensitive operations implement a gel pack collection program when shipping B2B. Due to pricing, it is not always feasible to collect used gel packs. For sustainability and environmental concerns we have our drain-friendly materials which are non-toxic and can be flushed down your drain.
What are the best shipping containers to use with gel packs?
For large gel packs, the most important factor you can control is how you insulate your cold packs. Our 2 piece box liners- PopupLiner and CelluLiner, provide unmatched protection for your shipments, ensuring 48-72 hours performance for products looking to stay chilled/refrigerated.
How do I choose the right size gel pack for my needs?
Gel packs should be able to fit the internal dimensions of your box accounting for an insulated box liner. Considering the weight of your product, determine how many gel packs to use to add ½ the weight in gel for every day the package will be in transit. Test your pack out using a data logger.
Dry ice vs gel packs
Two common methods for refrigeration during shipping are cold packs and dry ice. Cold packs are ideal for maintaining chilled temperatures (above 32°F), making them perfect for shipping items like chocolate or fresh foods that must remain cool but not freeze. Dry ice, on the other hand, is extremely cold (-109.3°F) and is best for keeping items frozen, such as ice cream or frozen meats.
Check out our article about dry ice vs gel packs for more details.
Smaller gel packs vs. Larger gel packs
Larger gel packs are ideal for companies with larger or more uniform items that cover the box end to end evenly designs, as they fit neatly above or below products. For shipments where space is uneven or limited at the top or bottom, smaller gel packs are more versatile, easily fitting into available spaces. Additionally, smaller gel packs offer more control over the amount of refrigerant used per item. While larger gel packs stay cold longer and streamline the packing process, smaller packs provide flexibility in packing configurations.
How to choose the right large gel pack
To choose the right large gel pack for your needs, start by considering the size and weight of your products, the internal dimensions of your packaging, and how long the shipment will be in transit. Larger gel packs, ranging from 48-96 oz, are ideal for companies using standardized box sizes as they provide longer-lasting cooling and reduce packing time. If your packaging has uniform spaces, large gel packs can fit neatly above or below products. The general rule is to use 1 pound of gel for every 2 pounds of product. For shipments requiring longer performance, such as pharmaceutical or grocery deliveries, larger gel packs are preferred due to their dense thermal mass and ability to maintain chilled temperatures for extended periods.
