Cold Chain Packaging: Insulated Boxes, Gel Packs and Dry Ice Requirements

Temperature-sensitive products — pharmaceuticals, biologics, fresh food, seafood, chocolate and dairy — require packaging that maintains target temperature from origin to destination. BestPackFactory manufactures corrugated outer shippers and coordinates cold chain inner solutions.

Temperature Zones

• Ambient (15–25°C): Most shelf-stable food, nutraceuticals, some cosmetics.
• Refrigerated (2–8°C): Fresh food, dairy, biologics, vaccines.
• Frozen (−18°C or colder): Frozen food, plasma, certain biologics.
• Controlled ambient (15–25°C, narrow): Chocolate, wine.

Insulated Packaging Options

• EPS (expanded polystyrene) foam box: Lowest cost, excellent insulation (R-value 3.8 per 25 mm). Widely used for frozen food and pharma. Not recyclable in most markets; increasingly restricted by retailers.
• Corrugated bubble-foil liner: Recyclable. Effective for 2–8°C over 24–48 hours with adequate gel pack volume. Lighter than EPS.
• VIP (vacuum insulated panel): Thinnest insulation for highest performance. Used for pharma clinical trials. Expensive (USD 30–100 per panel).
• Moulded pulp with reflective film: Emerging sustainable option for ambient-to-refrigerated range.

Gel Pack Sizing

Rule of thumb: 1 kg of gel pack (frozen at −18°C) absorbs approximately 300 kJ of heat. For a 2-8°C target in 30°C ambient over 48 hours, use approximately 0.5 kg of gel pack per litre of airspace inside the insulated box. Always validate with a temperature logger before launching.

Dry Ice for Air Freight

IATA DGR governs dry ice on passenger and cargo aircraft. Limit: 2.5 kg per package on passenger aircraft without special approval; up to 200 kg on cargo aircraft. Required label: Class 9 Miscellaneous hazardous goods (UN 1845). Must be in vented packaging. Contact your freight forwarder before shipping dry ice.

BestPackFactory Cold Chain Products

We supply custom-printed corrugated outer shippers with cold chain compliance markings (fragile, keep upright, temperature range labels) and can coordinate EPS or corrugated insulated liner sourcing through our partner network.