THERMOCON / GEL PACKS
Gel packs for temperature-controlled shipping
Coolant packs for food and pharmaceuticals: water-based with a melting point of 0 °C, or with a PCM melting point of −21 °C. Choose Basic, Pro or Recycling Gelpacks to suit your packaging and shipping process.
THREE OPTIONS
Which gel packs suit your shipping needs?
The three options differ in film material, melting point and suitability for food contact. Select an available size and the quantity you need on the relevant product page to submit your enquiry.
Gelpack Basic
For economical single-use applications
Mono-material PE film
Water-based · Melting point 0 °C
Suitable for direct food contact. The standard film is designed for cost-effective, single-use shipping.
Gelpack Pro
For greater mechanical demands
PA/PE composite film
Melting points 0 °C and −21 °C
Suitable for direct food contact. The tougher film also allows limited reuse when handled correctly.
Recycling Gelpack
With recycled content in the film
Mono-material PE film · 40% recycled content
Melting points 0 °C and −21 °C
Intended for indirect contact with packaged food. The film contains 40% recycled material and offers good mechanical strength.
Suitability for food contact depends on the specific variant and its conditions of use. Please request the product-specific compliance documentation for your application. The filling is not intended for consumption.
SIZE AND NOMINAL WEIGHT
Choose the right format
A gel pack must fit the available space and planned packout in your insulated box. Use the coolant pack finder to compare options by melting point, nominal weight and dimensions.
1. Define the temperature requirements
First, establish the permitted temperature range for your goods and the required shipping duration.
2. Narrow down the gel packs
In the finder, select Gelpacks as the pack type. Then narrow down the coolant and melting point to suit your application.
3. Enquire about your selection
Compare dimensions and nominal weights. Enquire about suitable products individually, or use the finder to select several products and submit a combined enquiry.
WATER-BASED OR PCM
0 °C or −21 °C: choose the right filling
Water-based gel packs · 0 °C
Available as Basic, Pro and Recycling Gelpack. The filling absorbs heat as it melts. For temperature-controlled shipping, the packout is matched to the product, insulation and shipping conditions.
PCM gel packs · −21 °C
Available as Pro and Recycling Gelpack. This filling is intended for suitable frozen shipping applications. Whether it can replace dry ice depends on the required product temperature and the complete packaging system.
Melting point is not product temperature. Neither 0 °C nor −21 °C automatically indicates the temperature of the goods. The achievable shipping duration depends on the coolant packs, packaging, payload, pre-conditioning and external conditions together.
Need a different melting point? Contact us to discuss the available fillings and pack types.
FOOD · FRESH PRODUCTS · E-COMMERCE
Cooling components for your food shipments
For meat, fish, delicatessen products or ready meals, choose gel packs according to the required product temperature, packaging and shipping duration. Depending on the system design, a PCM −21 variant may be suitable for frozen goods.
Basic and Pro are available for direct food contact. Recycling Gelpacks are intended for indirect contact. Also consider the available space, the stresses on the film and your daily packing process when choosing a pack.
Combine gel packs with the THERMOCON Paper Bag for a compact shipping solution. The appropriate packout is determined for your goods and shipping requirements.
PHARMA · BIOTECH
Design the complete packaging system around the required temperature
For temperature-controlled pharmaceutical and biotech shipments, the coolant pack, insulation, payload and packing instructions are considered together. It is this combination that determines thermal performance.
Cold-sensitive products in particular must not become too cold during packing. Coolant pack positioning, clearance from the goods and pre-conditioning must therefore suit the intended application.
Our pre-qualified systems provide specific packaging configurations with documented temperature control under defined test conditions.
PREPARATION AND USE
Pre-condition and pack gel packs correctly
Pre-conditioning
The pre-conditioning procedure specifies the freezing temperature and duration. Freeze gel packs lying flat and smooth so they can be positioned correctly in the box.
Define the packout
The required quantity and positioning of coolant packs are matched to the product, insulated packaging and shipping conditions.
Check before packing
Use only undamaged coolant packs. Place gel packs in the specified positions at the prescribed temperatures.
CUSTOM REQUIREMENTS
Custom sizes and printed film
Can’t find a standard format to fit your packaging? Custom sizes and individually printed film are available, subject to order quantity. Other melting points can also be requested for specific applications.
Tell us the format, temperature requirements, packaging, shipping duration and quantities you need. If you require custom printing, any existing artwork will help.
We will establish which combination of filling, film and format can be supplied for your application.
GEL PACK + INSULATED PACKAGING
Choose a matching insulated box
Gel packs and insulated boxes are selected together. The internal dimensions and packout must leave enough room for both the goods and the intended coolant packs.
Our range includes EPS insulated boxes and paper-based insulated packaging. The right option depends on factors such as the payload, shipping conditions and packing process.
CHOOSING GEL PACKS
Frequently asked questions about gel packs
How long do gel packs keep goods cool?
There is no single duration that applies to every shipment. The quantity of coolant, insulated box, payload, pre-conditioning and external temperatures together determine how long the required temperature can be maintained. A reliable assessment requires the specific shipping configuration to be considered.
Can gel packs be reused?
Basic is intended for single use. The tougher PA/PE film used for Pro allows limited reuse when handled correctly. The condition of the pack, hygiene requirements and application must all permit reuse. We will advise you on reusing Recycling Gelpacks for the specific variant.
What does 40% recycled content mean?
For Recycling Gelpack, this figure refers to the recycled content of the mono-material PE film. It does not describe the recycled content of the entire filled gel pack. The figure does not apply to Basic or Pro.
How should gel packs be disposed of?
The film and filling need to be considered separately. Basic and Recycling Gelpack use mono-material PE, while Pro uses a PA/PE composite film. Follow the product-specific disposal instructions and use the waste collection route specified for your application. Details for each variant are available on request.
Can PCM −21 °C replace dry ice?
This may be possible in suitable frozen shipping applications. It is not a universal replacement for dry ice. In particular, the product temperature, shipping duration and packaging configuration must be assessed.
How do gel packs differ from Foam Bricks?
Gel packs contain a gel filling in a film pouch. Foam Bricks have a foam core and retain their shape. The choice of pack type depends on how the coolant packs are arranged in the packaging and handled during packing.
Which gel packs do you need?
Tell us your product, temperature range, shipping duration and required quantities. An existing gel pack format or product code will help us select the right option.