When you're shipping something that needs to stay cold—like food, medicine, or cosmetics—keeping the right temperature is key. And that means knowing how many gel packs to include in your box.
Too few gel packs and your product could warm up before it arrives. Too many, and you're adding weight and cost for no reason. So how do you find the right number?
Don’t worry—it’s simpler than it sounds.
Let’s break it down step by step.
What Affects How Many Gel Packs You Need?
There are three main things to consider:
1. The Weight of Your Product
Heavier items usually need more cooling. A five-pound box warms up faster than a twenty-pound box.
2. How Long the Shipment Will Be in Transit
Short trips (under 12 hours) don’t need as much cooling.
But if your shipment is going across the country or takes 1–2 days to arrive, you’ll need more gel packs to keep it cold.
3. How Well Your Box Is Insulated
Is your product inside a cooler or thermal liner? Or just in a cardboard box?
Better insulation means the gel packs work longer. Poor insulation means you need more of them.
Simple Rule of Thumb
Here’s a basic rule that works well in most cases:
Use 1 gel pack for every 5 pounds of product.
If the trip is long (more than 12 hours), or your packaging isn’t insulated well, add one more gel pack.
Easy Reference Chart
Use this table as a starting point:
|
Product Weight |
Short Transit (Less than 12 hours) |
Long Transit (12 to 24 hours) |
|
5–10 lbs |
2 gel packs (16 oz each) |
2 larger packs (24 oz) or 3 regular (16 oz) |
|
10–20 lbs |
3 gel packs (16 oz) or 2 large (24 oz) |
4 large packs (24 oz) |
|
20–30 lbs |
4 large gel packs (24 oz) |
5 or more large packs (24 oz) |
Note: These are estimates. Every shipment is unique, so test and adjust based on your needs.
Where to Place the Gel Packs
It’s not just about how many gel packs you use—it’s also about where you put them.
A common mistake is to stack all the gel packs on top of the product.
Instead, spread them around—some on the bottom, sides, and top. That way, the cold air surrounds the product and keeps the temperature steady.
Why Getting This Right Matters
If your product arrives warm, you risk:
- Spoiled food
- Melted cosmetics
- Lost customers
- Refunds or wasted product
But when you pack it right:
- Your product stays cold
- Your customers are happy
- You avoid complaints and extra costs
Whether you ship one box a week or hundreds a day, taking the time to use the right number of gel packs helps protect your business and your brand.
Final Tip: Test and Adjust
Every product and route is different. Try a few test shipments with temperature monitors to see what works best for your situation.
Over time, you’ll build a system that works, and your shipments will be colder, safer, and more reliable.