Side Hustle Helper: Shipping With Cold Packs Vs Dry Ice: Comparison

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Maintaining temperature control is critical to shipping sensitive goods such as chilled and frozen food products, chocolates and many pharmaceuticals, but what method of refrigeration is right for you? Your primary options are cold packs vs dry ice. Making the best choice for your product can be as easy as considering the primary issues.

What is the desired temperature range for your shipment?​

Generally speaking, dry ice is the best choice for products that you need to keep frozen, while cold packs are best for maintaining the temperature of chilled goods above 32 degrees Fahrenheit (0 degrees Celsius). For example, in the food industry, the FDA requires that all raw protein perishable food items reach their destination at a maximum of 40 degrees F. Also, injectable medicines generally need to stay within 2-8 degrees C.

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Benefits of dry ice​

Firstly, did you know that often people assume dry ice is another form of water when actually the substance is a solid form of carbon dioxide sitting at -79 degrees Celsius? This is why dry ice is the best choice for any products you want to keep frozen as it stays much colder than gel packs, and for a much longer time.

Dry ice is extremely cold. It maintains a temperature of about -109.3°F (-78.5 degrees C) as it evaporates or sublimates and becomes carbon dioxide gas. Because of this property, it is ideal for products that do not have a low-temperature threshold. Dry ice can lower product temperature so that it stays frozen longer. Dry ice is commonly used for ice cream products and sorbet as well as frozen meats and seafood. But never pack dry ice with products that are sensitive to freezing, including live seafood, flowers, fresh food or certain pharmaceuticals. Also, it’s important to remember to ensure any food items shipped with dry ice are completely sealed to avoid dry ice changing the texture and taste of the product.

The benefits​

• Dry Ice lowers the product temperature so that it stays frozen for longer, making it most suitable for food products such as ice cream, frozen meats and seafood.
• When dry ice thaws, it does not turn into liquid it just sublimates or turns back into gas, this means you do not have to worry about your products getting wet.
• Perfect for long transport journeys, dry ice will keep your food products frozen solid until they arrive at the final destination.
• It is safer for the environment as dry ice turns into CO2 gas and completely disappears so there is no secondary waste.
• Dry ice can be more cost effective as you do not have to worry about reusing gel packs.

It is important to note that dry ice should not be used with products that are sensitive to freezing, including live seafood, fresh food or certain pharmaceuticals. Any food items shipped with dry ice should always be completely sealed so that the dry ice does not change the texture or taste of the product.

Dry ice can be dangerous to handle if you touch it without the right protection. For example, dry ice must never be handled with bare hands. It is always important to add the right safety and hazard labels to your package before you mail it full of dry ice. Overall, dry ice is a very helpful tool when handled correctly.

Benefits of cold packs​

If a product is perishable but must not freeze, cold packs are the best alternative to dry ice. Because cold packs are typically water-based, their phase change or melting point is around 32 degrees Fahrenheit. They do not reach 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 maintain the product in 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, as well as to supplement dry ice to 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. Another benefit of cold packs as a dry ice substitute is that they can also be added at room temperature during winter months to help prevent sensitive products from freezing.




Our cold packs can be made with custom print to match your brand.

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.

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. 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, 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.

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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.

Refrigerant Gel Packs for Shipping​

The first re-usable gel pack was developed in 1971, and was described as “a folding, wallet-sized plastic pouch containing a special liquid that stays either hot or cold for a long time.” It was designed to keep food and drinks temporarily cold, as well as for uses on body injuries. Today, gel packs are still the best dry ice substitute for products that must not be frozen solid, as they will not result in temperature damages. Gel packs usually maintain a product at 2 to 8 Celsius depending on the weight and starting temperature.

Made of refrigerant, thermoplastic materials, our gel ice packs provide a cost-effective way of keeping your shipments cold throughout the entire shipping duration. With a durable, leak-proof plastic design, our lightweight gel packs are perfect for shipping a large variety of goods. You can use our ice gel packs for shipping all types of temperature-sensitive goods, such as medicines and pharmaceuticals, and food items such as meat, cheese and groceries.

The benefits​

• The best option for quick deliveries and for products that do not need to be frozen solid such as fresh produce, dairy products, baked goods, chocolate, and some pharmaceuticals.
• As a single item, gel packs are easy to use and good for storage.
• For sensitive pharmaceutical items, gel packs will not contaminate the product unlike dry ice.
• They can be added at room temperature during the winter to help prevent sensitive products from freezing.
• Gel packs require no special handling safety guidelines unlike dry ice.
• Perfect option for meal kits and your customers can re-use them for other activities such as picnics.

To decide which temperature-controlled packaging solution is best for you, make sure you know the temperature your product needs to maintain during transit. Dry ice is the better choice when shipping food products that need to be frozen solid, whereas gel packs are more beneficial for shorter journeys such as same day or overnight shipping of more temperature-sensitive products like pharmaceuticals. If you need further information on what is the best option for you, contact our sales team today and we will be happy to help.

Available in custom sizes.​

A key benefit that sets us apart from other gel ice pack manufacturers is that our ice packs are available in custom sizes. Click below to view our selection of stock sizes of ice gel packs, or get in touch to discuss your specific requirements.
Minimum order quantities. Learn about our minimum order quantites for gel packs here.

As well as gel packs, GelTech is also available in the form of reusable plastic bins and baskets.

VIEW SUGGESTED SIZES VIEW BROCHURE GET A FREE QUOTE

Drain-Friendly​

Perfect for consumer deliveries, non-toxic and easy to dispose of in running water. Perfect for longer duration shipments with the need for easy disposal after use.

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Consumer​

Our consumer-grade cold packs are printed with safety labelling to ensure safe use.

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Sweat-Proof
Built with an advanced, layered exterior that minimizes condensation.

Blue Industrial​

Made with a tough, recyclable polyethylene plastic that is proven to be puncture-resistant and resist tears during rigorous handling.

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Custom-Printed​

Have your logo custom-printed onto your gel packs, ensuring complete consistency with your branding.

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CooLiner Insulated Box Liner

insulated shipping boxes can be used for shipping perishable food items, pharmaceuticals, dairy products, and any other temperature-sensitive products.

Made of recyclable #7 material*, CooLiner foil-insulated bubble bags are recommended for protecting refrigerated, carton-sized shipments against extreme ambient temperatures for up to 24 hours. When used together with a corrugated shipping box, the one-piece CooLiner creates an effectively insulated shipping box that arrives folded in a compact format for low-cost transport and storage.

Knowing that your temperature-sensitive products are protected against extreme temperatures throughout the cold-chain distribution system gives you the confidence to ship your goods in any season, to any location. Shipping with the proper type of 3D insulation means ‘product loss’ is much less of a concern.

Using the same innovative technology found in our foil-bubble thermal blankets and pallet covers, our gusseted insulated box liners use passive energy reflection to insulate your products throughout the entire shipping duration.

 

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Gel Packs vs. Dry Ice: Which Should You Use?​

It all depends on what you’re shipping.

While gel packs and dry ice can both keep your packages cold, they do so at different temperatures and for different lengths of time. So before you can choose between gel packs and dry ice, you have to think about what you’re shipping.

Here are a few examples of when gel packs work better and when you should use dry ice instead.

When to Use Gel Packs​

Gel packs are made of poly bags filled with either water or polymer gel. Because of this, they freeze and thaw at about the same rate as water. Depending on the type of gel packs you get, they may stay frozen for longer periods.

So while they can keep your frozen food cold, they will thaw a lot faster than dry ice.

You also have to think about what happens when these gel packs thaw. Since they are water-based, they may wet as they start to heat up. If you don’t have the right packaging materials, gel packs might get the box damp, which can damage it.

Because of these things, you should use gel packs for quick deliveries and for products that don’t need to stay completely frozen during the trip. This includes foods like:

• Fresh produce
• Cheese and other dairy products
• Baked goods
• Chocolate
• Bread

To get the most out of your gel packs, make sure you freeze your food before packing it and shipping it through the mail.

What to Use Dry Ice​

Dry ice isn’t actually ice at all. It’s made of frozen carbon dioxide, and it has a temperature of -109.3 degrees Fahrenheit. This means it’ll stay much colder than gel packs for a much longer period of time.

You also don’t have to worry about anything in your package getting wet when you use dry ice. When this ice thaws, it doesn’t turn into liquid. Instead, it sublimates, or turns back into gas.

Dry ice will keep your food products frozen solid until they arrive at their final destination. If you have to send something across the country or on a long journey, you should use dry ice.

It makes it an ideal choice for things like:

• Meat
• Seafood
• Medicine

The big problem with dry ice is that it can be dangerous to handle. If you touch it without the right protection, you can end up burning yourself. And since this ice lets off CO2 gas, you can have serious health problems if you breathe in too much.

Because of this, dry ice is considered a hazardous material when shipping. You’ll have to add the right safety and hazard labels to your package before you mail it full of dry ice.

While dry ice is a helpful tool, you have to be very careful when you use it.

How to Package and Ship Frozen Food​

Now that you know when to use gel packs and dry ice, you need to know the right way to package them. Without the correct packaging, they won’t be able to keep your food cold for as long as they can.

Here’s what you need to know.

Prepare Your Box​

Firstly, make sure you have a corrugated cardboard box. Then add a layer of insulated box liners around the edges. If you don’t have box liners, you can put a styrofoam container inside the box, or you can buy a foam insulated food shipping containers.

Line the Box with Gel Packs or Dry Ice​

Before you put your food inside the box, line the bottom and the sides of the box with your gel packs or dry ice. Fill any empty spaces or crevices with packing peanuts to keep anything from sliding around.

Add Your Food​

Set your frozen food in the middle of your package. If there is still empty space around your food, add more dry ice, gel packs, or packing peanuts.

It’s also a good idea to package your food in an airtight bag. This will help it stay colder for longer.

And again, make sure you freeze your food all the way through before you package it.

Seal the Box and Add the Right Labels​

Seal your box closed with heavy-duty packing tape. If you used dry ice, make sure you add the necessary labels.

Shipping Frozen Food Through the Mail: The Dos and Don’ts​

Before you start shipping frozen food in the mail, you need to make sure you know at what temperature the food needs to stay during the trip. Once you know how cold it needs to be, you can decide whether gel packs or dry ice is better for your package.

Most of the time, dry ice is a better choice when sending frozen food. Gel packs are helpful for short journeys (such as same-day or overnight shipping), but otherwise, you should only use these packs for items that don’t need to stay completely frozen.

 

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How Many Gel Packs Are Needed for Shipping?​

Gel packs, also known as cold packs or ice packs, are used in cold chain shipping to help maintain refrigerated temperatures for temperature-sensitive goods while in transit.
The types of temperature-sensitive goods that gel packs can help protect include pharmaceuticals, medical samples, meats, dairy products, beverages, pastries, fruits and vegetables.
However, as a supplier or distributor of such goods, you must consider some key factors to determine how much refrigerant should be used to maintain the desired temperature range for the full length of the shipping duration.
In this guide, we’ll discuss exactly how gel packs work and the various factors at play that determine their effectiveness. While there is no exact formula for calculating how many gel packs to use, this will give you a good idea of your needs.

How do gel packs work?​

Refrigerant gel packs are made using a gel solution that is frozen prior to shipment, and slowly thaw when subjected to temperatures above 1 °C. As they thaw, they absorb heat from the ambient air outside the package that may have penetrated to the inside, helping to maintain cooler temperatures inside the package. Once the gel packs have completely thawed to a liquid state, they no longer refrigerate the shipment.
The higher the temperature that the gel packs are exposed to, the faster they will thaw. This means that a larger quantity of gel packs would be required to refrigerate shipments that are exposed to higher temperatures.

Which factors impact the number of gel packs required?​

The number of gel packs that are required to maintain the desired temperature range for your shipment depends on various environmental factors. These include:

1. Insulated packaging type and performance​

The quality of the insulated packaging being used directly affects the quantity of gel packs required to maintain the desired temperature range throughout the shipping duration.

High-quality insulation, such as our PopupLiner material, requires fewer gel packs than low-quality insulation
High-performance insulated packaging, such as our PopupLiner material, features advanced technology that substantially reduces heat transfer. When using this type of high-performance insulation, less heat enters the package, and the gel packs inside the package are therefore subjected to lower temperatures and thaw at a slower rate. This means that a smaller number of gel packs can effectively refrigerate the shipment for a longer duration.
Insulated packaging that is less effective, on the other hand, allows more ambient heat to enter inside the shipment. This results in gel packs thawing at a faster rate, and a larger quantity of gel packs are consequently required to insulate the shipment

2. Ambient temperature​

The ambient temperature that a shipment is subjected to also has a significant bearing on the number of gel packs that are required.
If a package is subjected to extremely high ambient temperatures during shipment, more heat will enter the package, and a larger quantity of gel packs will be required to maintain a cool payload temperature.
If ambient temperatures are less extreme, on the other hand, gel packs inside the shipment will thaw more slowly, meaning fewer will be required to provide sufficient refrigeration throughout the transit duration.

3. Shipping duration​

Since gel packs thaw over time and lose their ability to absorb heat once they reach a liquid state, the shipping duration is a crucial factor in determining how many gel packs are required.
For shorter shipments (such as those of 24 hours or less), fewer gel packs are needed as they are likely to remain frozen throughout the shipping duration. For longer shipments (such as those from 48 to 96 hours), a larger quantity of gel packs will be required, wherein a prolonged thawing will keep the products cool throughout the shipping duration.

4. Payload size and target temperature​

The number of gel packs you need is directly related to the size of your payload and its target temperature range. Products that need to be kept colder, such as refrigerated meats, will need more gel packs than products that can be safely stored at controlled room temperature.
The number of gel packs required also increases based on the volume of products being shipped. A package containing a larger volume of products will require more gel packs than a smaller package.
As a general rule of thumb, for food and other dairy products it is recommended to use one pound of gel packs for every cubic foot of product with a target temperature of below 41 °F over a 24-hour period. The accuracy of this, however, will depend on ambient temperatures and the type of insulation used in the packaging.
The payload pre-shipment temperature is another key factor to consider. The temperature differential between the ice packs and the payload can affect the duration of thawing as well as condensation inside the package.

Placement of your gel packs is another important factor to consider​

Finally, how gel packs are placed inside the package is critical.
Maintaining a good fit will ensure that first, the gel packs do not over-chill products that can’t get too cold. Flowers, herbs and other produce cannot get too cold or they will be damaged, so they should be placed farther away or have a buffer between them and the ice pack. However, other items where cold temperatures are critical like meat, fish, chicken and other proteins can be placed close to or touching the ice pack.
During the shipment, gel packs soften as they thaw. This can cause movement or shifting inside the package and can therefore affect the performance that depends on the positioning of the ice pack. To prevent shifting, inserts and other dunnage can be used in the design of the pack-out.

 

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What Are Gel Packs?​

Credit: Insulated Products Corp​

A portable plastic bag filled with water, refrigerant gel, or liquid used to provide cooling is called a gel pack.

There are two types of gel packs. The reusable kind, which acts as a thermal mass and requires freezing, and the immediate type, which cools itself down using chemicals but can only be used once.

The instant type is typically used as a cold compress to relieve the pain of minor injuries, whilst the reusable type is used as a cold compress as well as to keep food cool in portable coolers or in insulated shipping containers to keep products cool during travel.

Benefits of Gel Packs​

1) Good for Products That Do Not Require To Be Frozen​

Cold packs are the best dry ice substitute for perishable products that do not require to be frozen. The melting point of gel packs is around 32 degrees Fahrenheit. They do not reach the severe cold temperatures of dry ice, so they will not cause temperature damage to objects that do not require freezing. Depending on the product's weight and beginning temperature, gel packs will normally keep the product's temperature between 2 and 8 degrees Celsius.

2) Gel Packs Are Good for Quick Deliveries​

Gel packs are ideal for products that do not need to travel vast distances. They're best for products that need to be delivered within a couple of hours. Fresh produce, cheese, and other dairy items, baked goods, chocolate, and bread are all examples.

Drawbacks of Gel Packs​

1) Lasts Only for a Couple of Hours​

Gel packs are not recommended for long journeys. When used in conjunction with ice and an insulated container, gel packs remain frozen for a maximum of 6 hours whereas dry ice packs last for a much longer time. As a result, they should only be used for short trips. While cold packs are great for products that do not require too much refrigeration, they're not suitable for products that require to stay frozen solid.

2) Melts Faster​

When shipping meat and fish items, melting and condensation can be a major problem. When something starts to melt, the surrounding water vapor transforms into its liquid form, which is known as condensation. Water can speed up the breakdown process and cause a plethora of problems, including mold and fungus growth on the products. Water-based freezing is used in gel packs, which greatly increases the danger of water contamination due to condensation.

What Are Dry Ice Packs?​

Credit: Nice Packs​

Dry ice is made by putting CO2 gas under pressure. The outcome is a frozen solid with a temperature of -78.5 C or -109.3 F. The product comes in a variety of sizes, including blocks, pellets, and snow. They are also available as ice packs.

Benefits of Dry Ice Packs​

1) They Don’t Become Wet When They Melt​

One of the biggest issues with gel ice packs is that when they melt, they fill your cooler with water, which sloshes around, spills everywhere, and makes your food soggy. There is no water to deal with dry ice packs, so your food is less likely to go soggy and water is less likely to leak out of your insulated container.

2) Ideal for Long Journeys​

Dry ice can lower the temperature of a product, allowing it to stay frozen for longer. Dry ice is frequently used for shipping ice cream products and sorbet, as well as frozen meats, frozen food, and seafood. Dry ice will keep your food products frozen solid until it reaches their final destination. It is ideal if you need to send something across the country or on a long voyage.

Drawbacks of Dry Ice Packs​

1) Not Suitable for Temperature Sensitive Products​

Because of the low temperature of dry ice, it should never be packed with products that are vulnerable to freezing. Live fish, flowers, and fresh food are examples of this. It's also vital to remember that any food items shipped with dry ice must be fully covered to avoid the texture and flavor of the product being altered by the dry ice.

2) It Has The Potential To Be Dangerous​

Since dry ice is so cold, holding it for more than a second can severely burn your skin and possibly induce frostbite if you're not careful. Always use gloves or cover your hands with a cloth when touching it.

 

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