Gel packs vs dry ice: Which is best for cold-chain shipping?
When shipping temperature-sensitive products like pharmaceuticals, frozen meal kits, and even chocolate, there are two primary ways to keep your product cold: dry ice or gel packs. In this article, we will examine the differences between dry ice and gel packs and explore which option is the best solution for certain applications.
TSS Thermalist
March 15, 2024 | R value, Sustainable Leadership
What is dry ice?
Dry ice is essentially frozen carbon dioxide. The surface temperature of dry ice is -109.3 degrees Fahrenheit, making it much colder than normal ice (which is 32 degrees Fahrenheit). And unlike normal ice which melts into liquid water, dry ice turns into carbon dioxide gas as it warms up. Because it is super cold and doesn’t melt into messy water, it makes it a good choice for refrigeration.
Dry ice has a surface temperature of -109.3°F
What are the advantages and disadvantages of dry ice?
Thanks to its super-cold temperatures, dry ice keeps products frozen for longer. This makes it a popular choice for items like ice cream, sorbet, frozen meats, and seafood. But because dry ice is so cold, it shouldn’t be used with items sensitive to freezing, such as live seafood, flowers, fresh food, or certain pharmaceuticals.
Dry ice is ideal for:
- Frozen meat
- Frozen seafood
- Certain pharmaceuticals
Additionally, dry ice needs to be handled with care. There are several things to be aware of when using dry ice. First, you should never touch it with bare hands. It is so cold that it will quickly burn your skin and lead to severe frostbite. You shouldn’t consume it either. This is not the type of ice you put in a glass of lemonade. And finally, you should never use it in small, poorly ventilated areas. Dry ice sublimates into carbon dioxide gas, which is poisonous.
“In general, it requires considerably more energy (heat) to convert dry ice from solid to gas than it does for gel packs from solid to liquid, which is why dry ice helps maintain lower temps for higher durations.”
Said Al Muzahimi, TSS Thermalist
What are the advantages and disadvantages of gel packs?
Gel packs, sometimes called cold packs or ice packs, are made from a gel solution that is frozen before shipment. When temperatures reach above freezing, they slowly thaw. As they do so, they absorb heat from the ambient air, which helps maintain cool temperatures inside the package.
Gel packs keep products within 2-8ºC
If a product is perishable but cannot freeze, gel packs are critical. Unlike dry ice, which reaches extremely low temperatures, gel packs do not dip to such extreme levels. Consequently, they won’t cause temperature-related damage to products sensitive to freezing. Gel packs typically sustain products within the 2 to 8 degree Celsius range, depending on factors like weight and initial temperature. Another advantage of using gel packs is shipping during winter months because they can be added at room temperature to prevent sensitive products from freezing. However, if products need to be kept at very low temperatures for a long time gel packs may not be the best solution.
Gel packs are ideal for:
- Fresh produce
- Cheese and dairy
- Baked good
- Chocolate
- Bread
- Certain pharmaceuticals
Unlike dry ice, gel packs do not require any special handling. In fact, our gel packs from TSS are made from non-toxic gel, making them safe for use with food, pharmaceuticals, and medical products. Shipping with dry ice must also meet certain regulatory considerations, whereas there are no regulations governing gel packs.
How to decide between dry ice and gel packs?
When deciding between dry ice and gel packs, begin by evaluating the temperature needs of your shipment and the advantages of each method. For frozen products, both dry ice and gel packs are viable options. Dry ice excels at sustaining frozen temperatures over extended periods, whereas gel packs serve as an efficient alternative for frozen shipments. However, if you’re shipping perishable goods above 32 degrees Fahrenheit, gel packs are the best solution.
What type of gel packs do we use at TSS?
Our gel packs are reusable and sustainable, and they protect temperature-sensitive products in ambient, refrigerated, and frozen temperatures.
- Heat-sealed linear low-density polyethylene wrapper.
- Cost-effective, reusable and durable.
- Available in drain safe options.
- Available in a variety of sizes, including custom sizing, depending on your specific needs.
“Our gel packs at TSS are environmentally friendly and ideal for maintaining refrigerated temperatures for longer durations, so we achieve two things: better performance while still being eco-friendly and sustainable.”
Said Al Muzahimi, TSS Thermalist
