Benefits of cold packs
If a product is perishable but must not freeze, cold packs are the best alternative to dry ice. Because gel packs are typically water-based, their phase change or melting point is around 32 degrees Fahrenheit. They do not phase change at extremely cold temperatures like dry ice, and therefore will not result in temperature damage to products that are sensitive to freezing. Cold packs will typically help maintain the product near the 2 to 8 degree C range, depending upon its weight and starting temperature.
Cold packs are also great for products that do not require too much refrigeration but need protection from mailing like certain cosmetics and chocolate. You can also use gel packs to protect against freezing, by using them at room temperature.
We offer a variety of cold packs including drain friendly gel packs and sweat proof gel packs. Our cold packs can be made with custom print to match your brand.
Our cold packs can be made with custom print to match your brand.
How many gel packs should I use to ship any given weight?
Generally, you want to pack a third of the weight of your product in gel packs/cold packs in order to reach 48 hour shipping. Exactly how many gel packs are needed for shipping will vary based on external temperatures, transport times and the quality of your insulator.
Combining Dry Ice and Gel Packs
You can add gel packs to a package trying to maintain frozen temperatures as a way to supplement dry ice and help slow down the sublimation process. As a result, cold packs can help prolong the life of dry ice and provide more extended coverage for frozen products in transit.
Handling safety and regulatory considerations
Handling safety
While cold packs require no special handling safety guidelines, dry ice must be handled with extreme caution because it is extremely cold. Skin contact with dry ice can lead to severe frostbite. Skin cells can very quickly freeze and become damaged. Use tongs to handle dry ice when possible, and use loose-fitting, thermally insulated gloves for manual handling. Never handle dry ice with bare hands.
When shipping products with dry ice to end consumers make sure to enclose the dry ice and provide clear and visible instructions regarding the dry ice. The goal is to know exactly how much dry ice you need in order to have the refrigerant fully sublimated by the time it arrives. In a case where dry ice remains at the end of the delivery it is important to design a system that prevents your customer from being injured.
Storage and disposal
When dry ice sublimates, it releases substantial amounts of CO2 gas. As a result, make sure to store dry ice in a well-ventilated location, as well as in a purpose-designed non-airtight container like our PopupLiner. When unpacking dry ice, dispose of it in a well-ventilated area. Do not place it in a sink or fixture where the extreme cold could result in damage to fixtures. Many cold pack materials (outer plastic shell), on the other hand, can be fully recycled at local collection depots. Check with your cold pack supplier to find out more.
Regulatory considerations Dry ice is considered a hazardous material in the United States. Non-medical shipments that contain more than 5.5 pounds) of dry ice must comply with Title 49 of the Code of Federal Regulations (49 CFR) or International Air Transportation Association (IATA) rules, depending on the mode of transportation. Where shipments are beneath this weight threshold, only minimal packaging markings are required, providing that the goods being chilled are not also hazardous. There are no regulatory requirements regarding cold packs.
Deciding between dry ice and cold packs
When choosing between dry ice and cold packs, start by considering the temperature requirements for your shipment and the relative benefits of each approach. If you are handling frozen products, you can use either dry ice or cold packs. While dry ice can maintain frozen temperatures for longer, cold packs are an effective dry ice alternative for frozen shipments. If you’re looking to ship perishable goods above 32 degrees Fahrenheit, cold packs are the superior option.