Cold chain packaging is one of the most difficult parts of shipping temperature-controlled products. Use too little coolant and products arrive thawed or warm. Use too much and you pay for extra material, heavier boxes, and higher shipping rates on every order.
The right answer depends on three things:
- Product temperature: Does it need to stay frozen, or just refrigerated?
- Time in transit: How many days will the box spend with the carrier?
- Weather: How hot or cold is it at origin, in transit, and at the doorstep?
Dry Ice: Best for frozen foods
Dry ice is solid carbon dioxide, and at about -109°F it is much colder than any gel pack. Instead of melting, it turns directly into gas, so it leaves no water behind to soak the box or the product. Although dry ice is considered a hazardous material, it is most effective at keeping frozen goods fully frozen. From prepared meals to pet food to desserts, dry ice provides the highest guarantee of arriving at the customer’s door frozen. If the right protocols and safety measures are followed, dry ice is often preferred by frozen food brands because it reaches those lower temperatures that alternative coolants cannot, especially when there’s multiple days in transit.
Gel Packs: Best for refrigerated foods
Gel packs are frozen before packing and slowly thaw in transit, holding products in the refrigerated range. FDA guidance calls for refrigerated food to stay at or below 40°F, and most brands target 33-40°F. Gel packs are a preferred option for refrigerated products that should remain within that range. Different companies offer various sizes and materials for gel packs. To practice sustainability, eGourmet Solutions prefers to use gel packs where the contents can be used for plants, and the outer bag is recyclable.
How eGourmet helps brands find the right pack-out
For brands new to cold chain shipping, or brands optimize their packaging, eGourmet Solutions offers heat chamber testing and test shipments. Our team builds and tests pack-outs for each client’s products, transit days, and seasons. We always stay fully stocked with boxes, curbside-recyclable insulated liners, Pregis bags, and coolants. As the weather changes, we adjust the pack-out, so your products stay protected all year.
Need help with your cold chain packaging? Talk to a team member today.
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