5 Key Things to Consider When Choosing Gel Packs

When it comes to cold chain logistics small decisions can have massive consequences. Whether you’re transporting vaccines, biologics, meal kits, or temperature-sensitive pharmaceuticals, the gel packs you choose play a critical role in maintaining product integrity.

But not all gel packs are created equal. From performance to sustainability, every detail matters. Making the right choice means not just protecting your products, but also protecting your business reputation and bottom line.

Here are five essential things to consider when selecting gel packs for your cold chain needs.

1. Temperature Requirements: Matching Gel Packs to Your Product

Every product has a specific temperature range it needs to maintain. Gel packs are designed to support those ranges, but the type you choose must align with the sensitivity of your goods.

For example, vaccines often require storage between 2°C and 8°C, while frozen goods like meal kits or some pharmaceuticals may need temperatures below -20°C. Advanced products, such as mRNA vaccines, demand ultra-cold conditions as low as -70°C.

Using the wrong gel pack – one that freezes or thaws at the wrong temperature – can result in disastrous temperature excursions. The key is to work with a supplier who offers gel packs tailored to specific thermal ranges and who understands your product’s needs.

Ask yourself: What temperature range does your product require? Does the gel pack provide reliable performance within that range?

2. Duration: How Long Do You Need the Gel Pack to Work?

Transit times aren’t always predictable. Delays at customs, unexpected traffic, or extended storage periods can all stretch timelines. Your gel packs must be able to maintain the necessary temperature for the full duration of the shipment.

Gel packs are rated for specific durations of performance, often depending on the surrounding conditions. A shipment traveling through hot climates, for example, will place greater demands on your cooling solution.

Pro tip: Always choose gel packs with a buffer. If your shipment is expected to take 24 hours, opt for a solution rated for 36 or 48 hours to account for unforeseen delays.

3. Packaging Compatibility: Will the Gel Packs Work With Your System?

A gel pack might perform perfectly on its own, but if it doesn’t integrate well with your packaging system, it could compromise the entire shipment. Insulated containers, passive shippers, or active cooling systems all have different requirements.

The size, shape, and weight of the gel packs must fit seamlessly into your packaging setup without creating inefficiencies. If they’re too large, they might crowd the container, leaving little room for product. If they’re too small or poorly placed, they might not provide even cooling throughout the shipment.

Work with your supplier to test gel packs in real-world scenarios. Simulations can help you identify potential weaknesses in your system before committing to a bulk order.

4. Environmental Impact: Can You Balance Performance and Sustainability?

Sustainability is no longer optional. Customers, regulators, and shareholders are paying close attention to how companies manage their environmental impact, and cold chain logistics is no exception.

Modern gel packs are increasingly designed with sustainability in mind. Options now include:

  • Reusable gel packs: Designed for multiple uses, reducing waste and lowering long-term costs.
  • Biodegradable materials: Made from eco-friendly components that break down naturally after disposal.
  • Recyclable designs: Created to integrate with existing recycling programs.

While sustainability is important, it should never come at the cost of performance. A biodegradable gel pack that fails to protect your products is no better than a standard one that performs. Seek solutions that balance environmental responsibility with reliability.

5. Supplier Expertise: Are You Partnering With the Right Team?

Not every supplier is equipped to meet the unique demands of cold chain logistics. When choosing gel packs, you’re not just selecting a product.

A reliable supplier will offer more than just off-the-shelf products. They’ll work with you to understand your needs, offer customized solutions, and provide support for troubleshooting or optimising your system. Look for suppliers with a proven track record in your industry and ask for evidence of product testing under real-world conditions.

It’s also worth considering whether your supplier aligns with your broader business goals, such as sustainability initiatives or innovation in cold chain technology.

Questions to ask your supplier:

  • Can they provide documentation of product testing?
  • Do they offer customised gel packs tailored to your needs?
  • How quickly can they scale production to meet increased demand?

Why It All Matters

Choosing the right gel packs isn’t just about protecting your products. It’s about protecting your reputation, minimising waste, and ensuring the reliability of your entire cold chain. A failure at this level can lead to spoiled goods, financial losses, and damage to customer trust.

By focusing on temperature requirements, duration, packaging compatibility, environmental impact, and supplier expertise, you’ll make smarter choices that strengthen your cold chain and position your business for success.

Final Thought: Invest in Quality

The best gel packs aren’t always the cheapest, but they’re worth every penny. When you consider the cost of lost products, regulatory penalties, and reputational damage, investing in high-quality gel packs is a clear choice.

Evaluate your current setup. Talk to your supplier. And ensure the gel packs you choose are up to the challenge. Because in the world of cold chain logistics, the smallest details make the biggest difference.

Thergis®