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How to Prepare Gel Packs to Ship Temperature Sensitive Products?

Gel packs can be used when shipping temperature-sensitive products to ensure that they remain within the appropriate storage range. The gel packs are designed to maintain a consistent temperature while in transit. By preparing gel packs, shipping companies can achieve a longer storage time for the products being shipped.

Packaging with gel packs begins by adding these packs between carefully wrapped insulated packaging material, such as bubble foil insulation, surrounding the product being shipped. The most important step in using this technique is to ensure that there are no open spaces or air gaps either on the sides or the top or bottom of the enclosed package. Once the gel packs have been added, they should be placed towards the outside of the box since they maintain their form inside a tightly packed box. After packing all items into a box, you will then need to apply an adhesive label that clearly lists what is inside the package.

Gel packs can be used in the following ways:

Frozen Solid Gel Packs

Frozen solid gel packs can be used for frozen or refrigerated products while dry ice is strictly used for frozen products. Frozen gel packs are usually for short term shipments less than 24 hours where dry ice can maintain the temperature range for several days. The gel packs can be placed directly beneath or on top of the product being shipped to ensure it remains at a temperature beneath the freezing point.

Conditioned Gel Packs

Conditioned gel packs are warm or thawed gel packs at room temperature. The process eliminates the initial freezing risk.

Cool Gel Packs

These gel packs are kept in the fridge and are not frozen. The risk of freezing is eliminated but does not offer the same protection of a frozen gel pack.


The process of transporting temperature-sensitive items includes a risk of the product being exposed to extreme temperatures during transit. Adhere to the rules below for proper shipping:

  • Use the appropriate temperature gel packs
  • Use the appropriate insulation to prevent temperature fluctuation during transit
  • Check the product’s status before it leaves your facility
  • Ensure that your shipping partner is aware of the specific temperature requirements
  • Instruct customer on proper handling of product
  • Monitor their usage in case issues arise

In conclusion, temperature-sensitive products must be handled with care. Shipping temperature-sensitive items with gel packs is a great cost effective way to ensure they reach their destination in top condition. Ensure you are properly preparing them for safe shipment through following the rules and be certain that all regulations surrounding the process are met. A temperature-controlled shipment is a very safe way to transport that product. Customers of the products must be aware of how to properly handle them, and employers must provide training on proper handling. Additionally, it is critical for safety reasons that everything possible is done to ensure you are able to monitor their usage of your product in case an issue arises.

Learn more about cold chain packaging here.

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*Minimum order quantity for insulated box liners is 500.