Can ice gel packs stay cold 48 hrs like dry ice?

Oui-ice gel packs stay cold 48 hrs like dry ice when you match PCM setpoint, isolation, and packout to your lane and validate with an ISTA‑style 48‑hour thermal test. Design frozen routes to ≤0 °F (−18 °C), choose −20/−23 °C PCM for “frozen‑class,” and use thicker EPS/PUR or VIP to stretch hold time. Then prove it with a data logger before scaling.

• When do ice gel packs stay cold 48 hrs like dry ice? (conditions, limits, profiles)

• Which PCM and insulation really hit 48 heures? (−23 °C PCM, EPS vs PUR vs VIP)

• How many gel packs do you need for 48 heures? (quick calculator and examples)

• Gel packs vs dry ice—what should you choose? (sécurité, rules, cost, use cases)

• 2025 trends that make 48 hours easier (VIP mainstream, prequalified kits, greener PCMs)

When do ice gel packs stay cold 48 hrs like dry ice?

Réponse courte: Ice gel packs stay cold 48 hrs like dry ice under a defined ambient profile (Par exemple, ISTA 7D) when you use the correct PCM setpoint (Par exemple, −23 °C for frozen), adequate insulation, and a top‑heavy, low‑void packout. Validate with a 48‑hour test and a logger.

Why this works: Gel packs release “cold” at their phase‑change temperature. Water‑based gels (~0 °C) suit chilled lanes; engineered PCMs at −20/−23 °C serve frozen lanes. If the setpoint is too warm—or insulation too thin—your reserve vanishes early. Use 2.0″ EPS/PUR for 36–48 h, or VIP hybrids for 48–120 h. For frozen food or ice cream, aim for ≤0 °F (−18 °C) throughout.

Which PCM + insulation deliver 48 heures?

Détails: For frozen‑class payloads, pair −23 °C PCM with 2.0″ EPS or PUR for ~48 h under moderate profiles; move to VIP panels to extend beyond 48 h or shrink box size. Pour réfrigéré (2–8 °C), +5 °C PCM bottles/gels plus VIP routinely achieve 48–120 h. Always request the thermal report (probe map, payload, ambient curve).

Practical tips you can apply today

• Pre‑condition PCM fully (Par exemple, ≤−23 °C for −23 °C packs) pour 24 à 48h.

• Pre‑chill the shipper so cold isn’t “spent” cooling foam.

• Top‑load most PCM: cold sinks; place thicker blocks above.

• Eliminate voids with kraft/foam to slow convection.

Field example: A dessert brand replaced 18 lb dry ice with −23 °C PCM in a 2.0″ EPS shipper and passed a 48‑hour summer profile with ≤2.8 °C variance across 6 probes—while avoiding dry‑ice airline issues.

How many gel packs for 48 hours so ice gel packs stay cold 48 hrs like dry ice?

Répondre: Start frozen lanes with PCM mass ≈ 0.8–1.2× payload mass in EPS and adjust for ambient and access. Use VIP to cut PCM mass or extend time. Always qualify on your route with a logger.

Copy‑paste calculator (Sheets/Excel):

• Base_lb_per_day (frozen): 10 for EPS, 8 for PUR, 6 for VIP

• Ambient_Factor: 1.0 cool / 1.2 warm / 1.4 chaud

• Insulation_Factor: 1.0 VIP / 1.1 PUR / 1.3 thin EPS

• Access_Factor: 1.0 no‑opens / 1.2 light / 1.4 frequent

Worked example: 48 H, warm route, PSE, light access →
=ROUNDUP((48/24)*10*1.2*1.3*1.2,0) = 38 lb of −23 °C PCM (distributed base/sides/top).

Packout layout that actually works

Step‑by‑step: Base PCM sheet → tight payload → side PCM/void fill → thick top PCM; bias more PCM to the “hot” exposure side (Par exemple, top/last mile). Cold falls; top‑heavy builds endurance.

Conseils pratiques & advice

• Summer lanes: Add 15–25% PCM or upgrade to PUR/VIP.

• Openings cost time: One open can burn 1–3 h of margin—design for minimal access.

• Document SOPs: Photos + weights = repeatability and fewer claims.

Gel packs vs dry ice—can ice gel packs stay cold 48 hrs like dry ice for everything?

It depends. Ice gel packs stay cold 48 hrs like dry ice for frozen‑class goods when you use −23 °C PCM and strong insulation; dry ice still wins for deep‑frozen (≤−60 °C) or very long lanes. Dry ice sits at −78.5 °C and is regulated for air transport; many PCMs are not dangerous goods (check the SDS).

Règles, sécurité, and what they mean for you

• Air limits: Most airlines cap dry ice near 2.5 kg (5.5 kg) per passenger/package; venting and marks required. PCMs typically bypass hazmat labeling.

• Product needs: Utiliser +5 °C PCM for 2–8 °C meds; −23 °C PCM for frozen foods; utiliser glace carbonique for ≤−60 °C or 72–120 h lanes.

• Evidence, not anecdotes: “48 h” should map to ISTA 7D (or similar) with probe maps and payload mass.

2025 developments and trends that help ice gel packs stay cold 48 hrs like dry ice

Trend overview (2025): VIP insulation is mainstreaming, delivering higher R‑value per inch and enabling 48–120 h holds with less PCM. Prequalified 24/36/48‑hour kits (chilled and frozen) are widely available, easing audits and speed‑to‑deploy. Greener PCMs and clearer airline guidance reduce hazmat friction.

Dernier progrès en un coup d'œil

• VIP kits: Smaller boxes, longer holds (48–120 h) for 2–8 °C and frozen lanes.

• Frozen‑class PCMs: −23 °C gels now standard alternatives to dry ice for 48‑hour routes.

• Smarter validation: Vendors publish rounded durations; detailed reports confirm true performance.

Perspicacité du marché: DTC food and pharma shipments are embracing prequalified VIP/PCM systems to reduce claims, shrink freight, and avoid hazmat paperwork—without sacrificing 48‑hour reliability.

Questions fréquemment posées

Q1: Can ice gel packs stay cold 48 hrs like dry ice in summer?
Yes—use −23 °C PCM, thicker insulation (PUR or VIP), and add a 15–25% PCM buffer; validate against a summer profile with a logger.

Q2: How many gel packs for a medium frozen box (48 H)?
Expect ~24–32 lb of −23 °C PCM in 2.0″ EPS for a medium payload; confirm with route testing and the calculator above.

Q3: Are gel packs hazardous like dry ice?
Typically no. Many PCMs are not regulated as dangerous goods; dry ice is regulated and requires venting and labeling. Check your SDS.

Q4: Do I still need a data logger if I qualify once?
Oui. Verification on your actual route (ISTA‑style) catches ambient swings and handling differences that lab tests miss.

Q5: Will 0 °C gel packs keep ice cream rock‑solid?
Non. Utiliser −20/−23 °C PCM (or dry ice for ultra‑cold/long lanes) and thicker insulation to arrive “hard frozen.”

Résumé & recommendations

Fin de compte: Ice gel packs stay cold 48 hrs like dry ice when you match −23 °C PCM, EPS→PUR→VIP isolation, and a top‑heavy, low‑void packout—and you validate under a 48‑hour thermal profile. Dry ice remains best for ≤−60 °C or very long routes, but PCM/VIP cuts hazmat complexity and often lowers total cost.

Étapes suivantes (CTA):

1. Define your target (frozen ≤−18 °C or chilled 2–8 °C).

2. Select PCM setpoint and insulation tier (aim VIP for toughest lanes).

3. Use the calculator to size PCM; build the “base/sides/top” sandwich.

4. Run a 48‑hour test with a logger; store the thermal report.

5. Roll out SOPs with photos and weights. Need a lane‑specific kit? Contact Tempk for a 15‑minute packout review and a tailored PCM mass chart.