Keeping medicines, vaccines and fresh foods safe isn’t easy. Temperature swings during transport can ruin a product or even harm patients. Koolit cold chain technologies provide a flexible toolkit of gel packs, foam bricks and phase change materials (PCM) that help you protect temperature sensitive goods from farm or factory to your door. In this guide you’ll learn why these solutions matter in 2025, how they work, and what innovations are transforming cold chain logistics. The global temperature controlled packaging market is forecast to climb from US$218.9 billion in 2025 to US$985.8 billion by 2034, so choosing the right solution is more important than ever.
Understand Koolit cold chain technologies: what foam bricks, paquetes de gel, gel bottles and PCMs are, how they differ and when to use each.
Learn proper usage and reuse practices: including preconditioning, placement and safe disposal for Koolit refrigerants.
Explore the latest cold chain trends: such as IoT sensors, AI driven routing, blockchain traceability and magnetic refrigeration.
Compare shipping scenarios: see which Koolit product fits different payloads and temperature ranges.
Gain market and sustainability insights: get the newest data on growth, regulations and sustainability milestones from CCT and Tower Cold Chain.
What Are Koolit Cold Chain Technologies and How Do They Work?
Koolit cold chain technologies are a family of passive refrigerant systems designed to maintain controlled temperatures during shipping. Unlike ordinary ice, which melts quickly and can damage products, Koolit refrigerants use advanced materials that absorb or release heat at specific temperatures. Este phase change process keeps your payload within a defined range and extends hold time. Koolit products include foam bricks, paquetes de gel, gel bottles and advanced phase change materials (PCM). Each has unique advantages:
Foam Bricks, Paquetes de gel, Gel Bottles and PCMs Compared
| Producto | Material & Composición | Temperature/Eutectic Point | Beneficio práctico |
| Foam Bricks | Water saturated foam encased in a plastic pouch | Freezing point 0 °C; stays frozen longer than ice | Maintains shape when frozen or thawed; ideal for tight fitting packaging |
| Paquetes de gel | Water soluble starch/cellulose gel in a plastic pouch | Freezing point 0 °C; eutectic point −0.4 °C | Económico, flexible and available in many sizes; good for general refrigeration |
| Gel Bottles | Blow molded high density polyethylene bottle filled with the same gel as gel packs | Freezing point 0 °C | Tough and puncture proof; suitable for rough environments and reuse |
| PCM avanzados | Organic compounds (alkanes, fatty acids and esters) that freeze and melt at specific temperatures | Temperature matched to payload (p.ej., 2–8 ° C, −20°C, +20 °C) | Allow smaller, lighter shippers and longer hold times; seguro y no peligroso |
How the Technology Works
Koolit refrigerants exploit the physics of cambio de fase. When a material freezes, it releases heat; when it melts, absorbe calor. Standard ice has a fixed melting point (0 °C), so it may overcool or undercool certain products. By designing refrigerants with different eutectic points (the temperature where solid and liquid coexist), Koolit can maintain specific ranges such as 2–8 ° C, −20 °C or even below −60 °C. Por ejemplo, Koolit’s 500 ST series uses a suppressed temperature gel made from carboxymethylcellulose with a eutectic point of −23 °C (−10 °F), making it a safe dry ice substitute for frozen shipments.
The refrigerant absorbs heat from your product and the surrounding environment until it reaches its melting point. Because the material’s temperature doesn’t change during phase change, your payload remains stable for many hours. PCMs are particularly effective because their melting points can be formulated to match the required temperature band. They also reduce shipping weight and allow for menor, more efficient shippers.
Consejos prácticos y recomendaciones
Tightly fitting packages: Usar foam bricks. They maintain their shape and provide uniform cooling in snug spaces.
General refrigerated goods: paquetes de gel come in a variety of pouch materials and gel structures. Choose them when cost and flexibility matter.
Wrap around protection: Saddle bags and mats offer form fitting protection around cylindrical items.
Rough shipping environments or repeated use: Gel bottles have a puncture proof blow molded shell, making them durable for multiple trips.
Envíos congelados: Usar el 500 ST gel packs as a dry ice substitute. They maintain sub zero temperatures without the hazards of solid CO₂.
Ejemplo del mundo real: En julio 2025 UNICEF shipped over half a million pneumococcal vaccines by sea from Belgium to Côte d’Ivoire. The sea voyage cut greenhouse gas emissions by 90 % y costos de flete por 50 %, demonstrating how innovation in cold chain logistics can improve sustainability without compromising product quality.
How to Properly Use and Reuse Koolit Refrigerants
Using a high performance refrigerant incorrectly undermines its benefits. Follow these guidelines to ensure safe handling, reuse and disposal.
Reutilizar, Recycling and Disposal
Koolit refrigerants are made from no tóxico, environmentally safe materials. Foam bricks, gel packs and PCMs can generally be disposed of via normal waste streams once the contents are removed. Sin embargo, reusability depends on physical integrity:
Gel bottles: Reusable as long as the bottle isn’t punctured or damaged.
Paquetes de gel y ladrillos de espuma.: May be reused under certain conditions. Implement an internal quality program to monitor weight and dimensions.
Reciclaje: Gel packs contain water soluble starch; after thawing, cut open the pouch and dispose of the liquid in a normal waste stream, then recycle the plastic pouch.
Desecho: If a refrigerant is punctured, dispose of the contents in accordance with local regulations. Liquid PCMs should be returned to CCT or disposed via oil recyclers because they are oil based.
Preconditioning and Handling
Proper preacondicionamiento ensures that your refrigerants will deliver the promised hold time:
Preconditioning time: For cool or frozen shipments, precondition gel packs, foam bricks and bottles in a freezer or refrigerator for 12–24 horas, y hasta 24–48 horas for a full case. Conditioning multiple pallets may take up to three weeks to ensure thorough freezing.
Ambient shipments: For shipments requiring controlled room temperature, precondition refrigerants in warm water.
Shelf life: Koolit liquid refrigerants have a two year duración, while gelled PCMs last three years. Foam bricks, gel packs and bottles will function indefinitely if undamaged.
Relación de peso: Apunta a un 1:1 a 1:2 ratio of product weight to refrigerant weight. Smaller payloads may require more refrigerant.
Colocación: Place at least one refrigerant on top of the product, because heat rises; for best performance, surround the product on all six sides.
Eutectic Points and Dry Ice Alternatives
Phase change materials freeze and melt at specific eutectic points. Regular gel packs freeze at 0 °C, with a eutectic point of –0.4 °C. Koolit’s 500 ST series uses a –23 °C eutectic mixture of carboxymethylcellulose. This suppressed temperature gel acts as a safer alternative to dry ice:
Hielo seco: Mantenimiento –78 ° C, but sublimates at 3–8 lbs per day and requires venting because it turns directly into carbon dioxide gas.
500 ST gel packs: Provide extended sub zero cooling without the handling hazards of dry ice and are available in multiple sizes.
Preconditioning Checklist
Inspeccionar refrigerants for damage. Discard punctured units.
Condición previa in a freezer/refrigerator or warm water depending on the desired temperature.
Verificar the product to refrigerant weight ratio.
Embalar refrigerants around the product, focusing on the top and sides.
Registro the freeze/melt dates to track shelf life.
Consejo: Label the top of your box to ensure it stays upright during shipping and fill void spaces with dunnage such as bubble wrap to reduce heat pockets.
Embalaje sostenible de cadena de frío: Trends and Innovations in 2025
The cold chain industry has undergone a digital and environmental revolution. To remain competitive, you need to understand the technologies and trends shaping 2025 y más allá.
Smart Sensors and IoT Adoption
Smart sensors monitor temperatura, humedad, vibration and location in real time. Their adoption is accelerating:
IoT adoption: Por 2026, acerca de 25 % of shipping containers will be equipped with IoT devices, up from ~4 % en 2023. Smart reefer containers are expected to increase sixfold to over 10 million units.
Big data: Global IoT connections will exceed 40 mil millones por 2034. Managing this data requires robust connectivity (satélite, celular, 5GRAMO) and analytics tools.
Beneficios prácticos: Sensors send alerts when conditions drift outside safe ranges, enabling corrective action before spoilage occurs. Choose suppliers whose systems integrate with cloud dashboards and train your team to interpret alerts.
IoT Adoption at a Glance
| Característica | 2023 Adopción | 2026 Pronóstico | Significado para ti |
| IoT sensors in containers | ~4 % of containers | 25 % of all containers | Real time tracking; fewer blind spots |
| Smart reefers | 1.6 million units | 10 million units | Better control of frozen and chilled cargo |
| Global IoT devices | 13.8 mil millones (2022) | >40 mil millones por 2034 | Greater data and connectivity demands |
Optimización de rutas impulsada por IA y análisis predictivo
Artificial intelligence transforms cold chain logistics by optimising routes and predicting failures:
Optimización de ruta: La IA analiza el tráfico, weather and demand to suggest the most efficient routes. Studies suggest it can cut fuel usage by up to 15 % and improve fleet efficiency por 20 %.
Mantenimiento predictivo: AI monitors equipment data to anticipate failures, allowing you to schedule servicing only when necessary.
Previsión de la demanda: Models such as ARIMA help forecast demand and temperature deviations so you can allocate resources effectively.
Blockchain para trazabilidad y cumplimiento
Blockchain technology creates a tamper proof ledger for every transaction and environmental condition. Cuando se combina con sensores de IoT, blockchain records temperature, Ubicación y manejo de eventos., ensuring transparency and trust among stakeholders. Los beneficios incluyen:
Simplified audits and dispute resolution.
Compliance with Good Distribution Practices (PIB) and FSMA by providing verifiable data.
Real world use: Smart containers using blockchain maintained vaccine safety during shipments from Brussels to Mumbai.
Advanced Refrigeration and Energy Efficient Cooling
Innovations in refrigeration reduce energy consumption and greenhouse gas emissions:
refrigeración magnética: Magnetic systems are 20–30 % more energy efficient than traditional compressors and could cut energy use and emissions by up to 60 %. The market for magnetic refrigeration is forecast to grow from US$0.51 billion in 2024 to US$9.40 billion by 2032.
Solar powered cooling: In rural regions, solar cold storage units deliver stable temperature control without unreliable grids. Los EE. UU.. Energy Information Administration reported commercial electricity prices of 13.10 cents per kWh in 2024, while solar generation can cost 3.2–15,5 céntimos por kWh. Some units reach –25 °C in 30 minutos.
Sustainable and Smart Packaging
Packaging is no longer just insulation; it’s a technology platform:
The cold chain packaging market, valorado en US$34.28 billion in 2024, se espera que alcance US$89.84 billion by 2034, una CAGR de 11.3 %.
Sistemas reutilizables: Reusable cold chain packaging will grow from 4.970 millones de dólares en 2025 a 9.130 millones de dólares EE.UU. 2034.
Materiales: Paneles aislados al vacío, polyurethane foam and seaweed based bioplastics improve insulation while reducing waste.
Indicadores inteligentes: Etiquetas RFID, QR codes and AI powered sensors change colour if temperature conditions are breached. These technologies reduce spoilage and enhance compliance.
Renewable Energy and Carbon Neutral Transport
Sustainability goals are driving the adoption of renewable energy and low carbon transport:
Global rules: The International Maritime Organization requires a 40 % reduction in carbon intensity by 2030 y 70 % por 2050.
Electric and hybrid vehicles: Coupled with AI optimised routes, electric trucks lower fuel consumption and emissions.
Shared logistics hubs and cross docking: These practices reduce empty miles and maximise resource use.
Renewable microgrids: In remote areas, solar microgrids can power refrigeration and IT systems sustainably.
Regulatory Changes and Market Expansion
Regulations tighten every year. Notable changes in 2025 incluir:
End of the De Minimis Rule: A NOSOTROS. shipments under US$800 from China and Hong Kong are no longer duty free.
EU Digital Product Passport: Goods sold in the EU must carry detailed information about origin and environmental impact.
Import Control System 2 (ICS2): Requires advanced shipping data for improved security.
Market expansion has been robust:
CCT expanded its Asia Pacific presence with new hubs in Tokio y Bombay in August 2025, and partnered with E&I Cooperative Services to serve universities and research labs.
Sonoco invested US$30 million to expand temperature controlled packaging capacity.
DS Smith launched TailorTemp, a modular solution for pharmaceuticals at Pharmapack Europe 2025.
Eutecma and PLUSS Advanced Technologies introduced new reusable pallet and VIP shippers.
Sustainability Achievements in 2025
Tecnologías de la cadena de frío (CCT) and Tower Cold Chain have reached impressive sustainability milestones:
CCT exceeded its target of 100 million pounds of landfill avoidance by 2025, achieving this goal a year early. The company completed more than 12.5 million shipments using reusable packaging.
Tower Cold Chain earned the EcoVadis gold medal, placing it in the top 5 % of businesses recognised for sustainability.
CCT’s acquisition of Tower Cold Chain in October 2024 expanded its product range and accelerated innovation.
Both companies provide advanced track and trace platforms and are developing tools such as carbon calculators and sustainability hubs.
Update note: All data and trends in this article reflect information available as of Noviembre 23, 2025, ensuring you have the latest insights.
Choosing the Right Koolit Solution for Your Needs
Selecting an appropriate refrigerant is like choosing the right clothing for changing weather – your choice depends on temperature, duration and activity level. The same logic applies to cold chain packaging. Use the decision guide below to match your product and journey with the appropriate Koolit solution.
Decision Guide
| Shipping Scenario | Rango de temperatura & Duración | Recommended Koolit Product | Why It Fits |
| Valuable pharmaceuticals requiring 2 °C–8 °C under demanding conditions | 2–8 °C for 2–5 days | KoolTemp PUR containers with foam bricks | Modular design allows reuse; high R value insulation with foam bricks ensures stable 2–8 °C. |
| General temperature sensitive goods (alimento, diagnóstico) | 2–8 °C for 12–24 hours | KoolTemp EPS insulated containers with gel packs | EPS provides lightweight insulation; gel packs are economical and flexible. |
| Pallet sized loads (large shipments) | Various ranges up to 120 horas | KoolTemp insulated pallet containers with Koolit bricks | XPS (EXP) walls and bricks offer uniform thermal protection across large payloads. |
| Small parcels or clinical samples | 2–25 °C for 12–24 hours | KoolTemp insulated envelopes plus gel packs | Compact design with gel packs maintains temperature during short haul deliveries. |
| Frozen vaccines requiring −20 °C or below | −20 °C to −23 °C for 24–48 hours | Koolit 500 ST series gel packs | Suppressed temperature gel provides dry ice like performance without sublimation. |
| Long haul pharmaceuticals requiring multiple temperature zones | <−60°C, −20°C, +5 °C, +20 °C; arriba a 120 horas | CCT Tower Elite reusable pallet shipper | Accepts Euro and US pallets; uses PCM plates or dry ice for four temperature ranges; integrated IoT monitoring. |
Herramienta de autoevaluación
To identify the ideal Koolit solution, ask yourself these questions:
What temperature must my product maintain? (Congelado, refrigerado, room temperature)
How long is the transit? (Hours or days)
What is the payload size? (Paquete pequeño, paleta)
Will I reuse the container? (Yes or No)
Are there regulatory requirements? (Productos farmacéuticos, diagnóstico)
Using your answers, match them to the decision guide above. Por ejemplo, if you’re shipping a 500 kg batch of biologics requiring +5 ° C para 4 días, choose the CCT Tower Elite with PCM plates tailored to +5 °C. If your product is a small diagnostic sample shipped overnight, a KoolTemp envelope with gel packs suffices.
Ejemplo de caso: CCT Tower Elite
El CCT Tower Elite is a new reusable, temperature controlled pallet shipper launched in April 2025. It holds 1600 l and fits both Euro and US pallets. With four temperature ranges (<−60°C, −20°C, +5 °C, +20 °C) it maintains product integrity for encima 120 horas sin alimentación externa. Its integrated IoT system provides real time temperature monitoring and asset management, while its lightweight design offers cost and energy savings. By combining Tower Cold Chain’s reusable expertise with CCT’s PCM technology, the Tower Elite exemplifies how modular, multi temperature solutions are reshaping large scale logistics.
Latest Developments and Trends in Cold Chain Technology (2025)
Resumen de 2025 Desarrollos
Crecimiento del mercado: The temperature controlled packaging market will grow from US$218.9 billion in 2025 to US$985.8 billion by 2034, con una CAGR de 18.2 %.
Technology shift: Non water PCMs are replacing traditional ice, offering more reliable temperature stability.
IoT and analytics: Integration of IoT sensors and data analytics provides real time monitoring and risk mitigation.
Sostenibilidad: Reusable and modular packaging systems reduce waste and cost; CCT avoided 100 million pounds of landfill ahead of schedule.
Investment and partnerships: Companies like Sonoco and DS Smith are investing in capacity and launching new solutions. CCT expanded into the Asia Pacific with new hubs in Tokyo and Mumbai.
Regulatory changes: Nuevos Estados Unidos. and EU rules tighten compliance, emphasising detailed product tracking and environmental reporting.
Ideas del mercado
The cold chain market is booming due to the convergence of biologics, e commerce and globalised supply chains. Los analistas proyectan el mercado de la cadena fría may reach US$1.2 trillion by 2033. China alone demanded 365 million tonnes of cold chain capacity in 2024, and similar growth is occurring in India and Southeast Asia. This growth demands investment in infrastructure, regulation compliance, and advanced technologies.
Temperature classes play an important role in selecting packaging. Almacenamiento congelado (≤ 0 °C) preserves meat and seafood, while chilled storage (0–5 ºC) slows ripening for produce. Temperatura ambiente controlada (10–25°C) protects pharmaceuticals and chocolates, and ultra cold storage (≤ −70°C) is essential for mRNA vaccines.
To remain competitive in 2025, consider adopting monitoreo en tiempo real, Logística impulsada por IA, trazabilidad de la cadena de bloques y embalaje sostenible. Invest in solar powered or magnetic refrigeration, expand reuse programs, and prepare for evolving global regulations.
Preguntas frecuentes
Q1: Are Koolit refrigerants non toxic?
Sí. Koolit foam bricks, gel packs and PCMs use water or organic materials that are no tóxico and safe for disposal in normal waste streams. Liquid PCMs may require special oil recycling procedures.
Q2: What’s the difference between foam bricks and gel packs?
Foam bricks are water saturated foam that maintain their shape and stay frozen longer, making them ideal for tight spaces. Gel packs use a water soluble starch gel; they are flexible, economical and suitable for general use.
Q3: How long do Koolit refrigerants stay cold?
Depending on external conditions, paquetes de gel, foam bricks and gel bottles can stay cold for 12–24 horas or longer when used within insulated containers. Foam bricks provide the longest cooling time.
Q4: Do Koolit refrigerants require preconditioning?
Sí. Refrigerants must be preconditioned in a freezer or refrigerator for 12–24 horas (or longer for bulk loads) to achieve the desired temperature. For ambient shipments, precondition them by placing in warm water.
Q5: Can the 500 ST gel pack replace dry ice?
Sí. El 500 ST series has a eutectic point of −23 °C and can keep payloads below freezing without the handling hazards of dry ice.
Resumen y recomendaciones
Choosing the right cold chain solution is vital to protect your products, reduce waste and comply with evolving regulations. Koolit cold chain technologies offer an adaptable toolkit – foam bricks for tight fitting packages, gel packs for general use, gel bottles for rugged conditions and PCMs for precision temperature ranges. These refrigerants are non toxic and reusable, but proper preconditioning, placement and ratio are essential. En 2025, digital tools like IoT sensors, AI powered route optimisation and blockchain are transforming logistics. Prácticas sustentables, including reusable packaging and renewable energy, are no longer optional; they drive cost savings and meet regulatory demands. Finalmente, the market is growing rapidly, with CCT, Tower Cold Chain and others leading innovations in reusable pallet shippers and sustainability achievements. By staying informed and adopting these technologies, you can ensure product integrity and operational efficiency.
Plan de acción
Evalúe los requisitos de su producto: Determinar el rango de temperatura, duration and payload size. Use the decision guide to choose the appropriate Koolit product.
Implement quality programs: Inspect and precondition refrigerants correctly. Monitor shelf life and reuse criteria.
Adopte un monitoreo inteligente: Invierta en sensores de IoT, AI analytics and blockchain tools to gain real time visibility and ensure compliance.
Commit to sustainability: Replace single use EPS containers with reusable systems. Consider magnetic refrigeration or solar units to reduce energy consumption.
Prepare for regulation: Stay ahead of changes like the EU digital product passport and the end of the De Minimis Rule. Work with logistics partners who provide transparent data and certified compliance.
Involucra a tu equipo: Capacitar al personal sobre el manejo adecuado., monitoring and data interpretation. Encourage continuous improvement and sustainability initiatives.
Acerca de Tempk
Somos Templ, specialists in temperature controlled packaging and cold chain solutions. Our focus is delivering reutilizable, eco friendly cold chain products tailored to pharmaceuticals, biológicos, food and research logistics. With a robust R&D program and advanced manufacturing, we produce gel packs, bolsas aisladas, VIP boxes and pallet covers that meet stringent regulatory standards. Our innovations include smart sensors and data logging devices that integrate seamlessly into our packaging, offering real time visibility and predictive analytics. We believe in sustainability, investing in recyclable materials and reusable systems that help clients reduce landfill waste and carbon footprint.
Cómo podemos ayudarte
If you’re ready to modernize your cold chain, Templ offers tailored support. Whether you need to design a pre qualified shipping system, implement IoT enabled tracking or switch to reusable packaging, our experts will guide you. We invite you to contact us to discuss your specific needs and discover how our solutions can optimize your operations.
This guide was last updated on November 23, 2025 to reflect the most current data and best practices.
