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Refrigerated gel packs
The refrigerated gel packs are created mainly for cooling food items during transit. These packs incorporate a water and gel mix that forms a chilly, solid state on refrigeration. They are widely utilized in such industries as food and pharmaceutical shipping, where temperature regulation is essential. They are also marketed in convenient sizes that can easily fit into food containers.
Room temperature gel packs
A room temperature gel pack is intended to protect food from excessive heat during shipment. These gel packs are recommended for insulation instead of refrigeration, as they help to maintain food at recommended storage temperatures. Best suited for shipping non-perishable food products such as baked goods and dry foods, room-temperature packs are effective when used in mild to moderate weather conditions.
High-performance gel packs
High-performance gel packs include a larger concentration of gel solution for better thermal retention. These are well suited for outdated timelines; However, they are heavier and bulkier than standard gel packs. They are recommended when foods sensitive to temperature require shipping or when there are forecasted extended delays in delivery.
Custom-sized gel packs
These are created to order, depending on the pack's dimensions or client needs. Custom gel packs can be designed to fit specific shipping containers or accommodate food with unique storage needs. These customizable options ensure maximum efficiency in temperature control during transportation.
Reusable gel packs
Gel packs for one-time use are typically thrown away after one use. However, gel packs are reusable for multiple uses, which need to be frozen or chilled again to be used. Reusable gel packs are eco-friendly and convenient for distributions with regular and frequent shipping schedules.
Gel packs incorporate several key design features that enhance their effectiveness in maintaining temperature during food transportation.
Material of the outer casing
Gel packs for food transportation come stored in puncture-resistant plastic coverings. The materials include PVC, polyethylene, or nylon. All these materials have excellent insulation retentivity and flexibility. PVC gel packs are known for being heavy-duty, while polyethylene packs are lightweight and economical. Nylon gel packs are meant to be tear-resistant and durable to provide long-lasting service.
Gel formulation
The very formulation of the gel is key to pack performance. A gel pack incorporates a water and gel mix to create a thick liquid that is distributed inside the pack. The higher concentration of gel ensures better thermal conduction and retention. Some gel packs for shipping food comprise non-toxic gel material that will be recommended for shipping perishables and pharmaceuticals.
Sealing methods
Gel pack efficacy involves ensuring that the gel remains inside and that the pack undergoes contamination during shipment. This is achieved through tight seal designs which ensure no puncturing of the pack. Common sealing methods include heat sealing and ziplock closures. Ziplock gel packs are usable for resealing.
Size and shapes
Gel pack sizes range from small, 6 inches by 4, to large, 12 inches by 10, depending on the need or client preferences. Thin varieties are suited to chill small food items such as surgical masks and food in smaller containers, while thicker gel packs maintain the temperature of larger shipments for extended periods. Shapes are compatible with the type of container or packaging used for shipping. For instance, a pack suitable for a box will be flat-narrow, while a container will be a cylindrical shape.
Storage and shipping instructions
All gel packs must be frozen before use. After freezing and solidifying the gel inside, they must be placed into the container with food to be shipped. Packs must be placed above and below or on all sides of the food to provide all-around cooling. Resealable gel packs allow you to remove air and tightly seal them after usage to prevent pack contamination.
Gel packs find extensive uses across various scenarios in the realm of food transportation.
Shipping perishable food
Gel packs serve their best purpose in maintaining the right temperatures for perishable food such as meat, dairy products, seafood, and fresh produce during shipment. When delivering groceries, temperature control must be maintained. Gel packs also regulate the temperature of these foods during transit from the manufacturer to the retailer.
E-commerce food deliveries
Food delivery services are very popular these days. Gel packs are very critical in ensuring food items remain at appropriate and required temperatures during transit. This practice will guarantee that the meal is delivered fresh and at the right temperature, which is critical for businesses.
Meal kit services
Many companies deliver ingredients and recipes in good time for customers to prepare meals. Gel packs are used to maintain the required temperature and freshness during transit. Meal pack kits comprise chilled items such as meats, fish, and vegetables with temperature-sensitive gel packs. Customers enjoy the convenience of delivering these meal kits promptly without compromising food quality.
Floral and baked goods shipping
Apart from perishables, gel packs are used for the shipment of flowers and baked goods. When shipped, fresh-cut flowers need to be controlled at low temperatures to reach optimal freshness. Similarly, baked goods such as cakes and pastries undergo temperature control to avoid spoilage, for instance, in icing or cream fillings.
Special diet foods
Gel packs are useful in shipping foods with special requirements, such as gluten-free, vegan, organic, or keto diets. Maintaining the appropriate temperatures for these specialized food products during transport will prevent loss of product potency and ensure timely delivery with minimal disruption to the service.
Some main differences may be in the specifications of gel packs, depending on the brand, intended use, and pack sizes. There are, however, some common features and maintenance practices that are fundamental to all gel packs.
Gel content
The gel content is a blend of water and proprietary gel solution that is thick and viscous. The solution readily freezes and creates a super chill environment around the food item. Higher concentrations of gels are known to better maintain the lower temperature when delivering food that requires special handling and storage attention.
Temperature range
Gel packs are typically stored in a standard freezer at a temperature of -18°C. For optimal performance, gel packs should be stored in high-performance freezers that carry -20°C. This is the working temperature range for most gel packs. At this temperature, gel packs harden to contain a solid gel that easily breaks or shatters and cannot release any cooling energy. Under normal circumstances, home freezers maintain a range of temperature between -10°C and -30°C. Such home freezers are best suited for shipping food that requires a non-perishable nature or a short-distance shipment. However, commercial gel packs for high-demand customers are normally stored in industrial freezers, where the temperature is maintained at -18°C.
Size and thickness
Gel packs come in different sizes, from small ones with a capacity of 200 milliliters to larger ones that can take up one liter of gel. Their thickness ranges from 1 millimeter to 20 millimeters. Thin gel packs freeze faster but are also short-lived in sustaining cooling action. Thick gel packs, on the other hand, take longer to freeze, but once they are chilled, they take a longer time to release cooling energy.
Hygiene and sanitation
Care and hygiene of gel packs are especially very critical since they are used for food shipment. Always wash your hands to prevent contamination before handling gel packs. It follows that the outer pack must be cleansed using running water and soap or disinfectant solutions. This is an important practice to prevent the spread of disease along the foods.
Repairs
Although they rarely require repair, gel packs may develop punctures, rips, or tears. These damages have been observed to be at times repaired; however, the sustaining gel may be released in the repair process and expose the pack to contamination. Repairing gel packs through professional service or as a DIY project by applying adhesive patches are common procedures. Relying on gel packs of any kind that have been repaired is not recommended because they have been proven to be less effective and hygienic.
Replacement
Long-term use of gel packs involves inevitable replacement. This is so because the inner gel will break down, and the outer casing will wear out. Gel packs that show noticeable defects and reduced efficiency should be replaced. In general, companies should be ready to accommodate frequent pack replacements to always maintain optimal performance.
Gel packs can be reused many times since they are designed to retain as much temperature as possible for a long time. All that needs to be done is pack the ice cooler with the gel packs after they have been frozen, and they are ready to be used again for another shipment. Reusable gel packs are inexpensive and eco-friendly.
This duration depends on different factors, such as the type of food being shipped, the ambient temperature during transit, and the efficiency of the cooling system. On average, gel packs can maintain the required temperature for perishable food for up to 48 hours. However, under ideal conditions, gel packs can keep food fresh for more than 72 hours.
Gel packs are ideal solutions for shipping frozen foods since they retain low temperatures for a longer period. In addition, the gel inside the packs is non-toxic and safe, making it possible to transport food products that need to be shipped at low temperatures.
Both gel packs and dry ice are ideal as refrigerants. However, dry ice releases extremely low temperatures, making it suitable for long-distance shipping of products such as vaccines that require freezing temperatures. On the other hand, gel packs are easier to handle, non-toxic, and more eco-friendly.
Yes, gel packs can be personalized based on specific sizes, shapes, or temperature ranges that are best suited for special foods that require handling during shipment. Nevertheless, customization will be made based on performance and efficiency requirements.
