How many gel packs do you need? Complete calculation formula

How many ice/gel packs do you need? A complete calculation formula

One of the most frequently asked questions by our customers: 'How many coolants should I use for my shipment?' Too few means risk of spoilage, too many means unnecessary shipping costs and weight.

The basic formula

For a typical 24-hour shipment at normal outdoor temperatures (15-20°C):

Gel packs needed (grams) = Product weight (grams) × 0.2

So: 5 kg of meat × 0.2 = 1 kg gel packs (e.g., 2 or 3 packs of 400g)

Adjustment factors

Transport time

• 12 hours: multiply by 0.5
• 24 hours: standard (1.0)
• 48 hours: multiply by 1.8
• 72 hours: multiply by 2.5

Outdoor temperature

• Winter (0-10°C): multiply by 0.7
• Spring/autumn (15-20°C): standard (1.0)
• Summer (20-25°C): multiply by 1.4
• Hot summer (25+°C): multiply by 1.8

Box insulation

• EPS box 30mm wall: standard (1.0)
• EPS box 50mm wall: multiply by 0.7
• Honeycomb box: multiply by 1.2
• Standard cardboard box: multiply by 2.5

Example calculation

You are shipping 3 kg of fish, 48 hours transport, summer (24°C), EPS box 30mm wall:

3000 g × 0.2 = 600 g base
600 × 1.8 (48 hours) = 1080 g
1080 × 1.4 (summer) = 1512 g

Result: about 1.5 kg of gel packs needed. That is, for example, 4 packs of 400g.

Pro tips

• Distribute the gel packs around the product — not just on one side
• Place on the product (cold sinks) for fresh products
• Always use absorbent pads to catch meltwater
• Pre-freeze the gel packs for at least 24 hours
• Test your packaging with a data logger if in doubt

Table: quick reference

Still unsure?

For specific calculations for your use case, you can contact our internal sales department. We have experience with thousands of customer situations and are happy to help.