5 Common Mistakes in Chilled Shipping
Short answer: the five most common mistakes in chilled shipping are: choosing a box that is too large (more air means faster warming), dosing ice packs wrongly, putting ice directly on frost-sensitive products, not using an absorbent pad, and outer packaging that is too light. Below, the solution for each mistake.
Good cold chain packaging seems a simple choice, but in practice many shipments go wrong through packaging that does not suit the shipment. Our advisers see the same mistakes again and again. At the end of this article you will find a checklist and answers to frequently asked questions.
1. Choosing a box that is too large
A common mistake: you choose a larger box to pack the contents comfortably. But insulation works by slowing down heat transfer. The more air there is around your product, the more heat has to be held back. A smaller box with less air inside is almost always better insulated. Our advice: choose a box that fits, not one that is roomy.
How to prevent it: measure your product including inner packaging, add the space for cooling elements and choose the smallest box in which everything fits. Fill any remaining space. The full explanation is in choosing the right box size. You will find an overview of the sizes with our EPS boxes.
2. Too few or too many ice packs
Many customers reason: more is better. But ice packs take up space and can freeze the contents when that is not the intention. For shipments at 2 to 8 °C that are only a few hours in transit, a single gel pack may be enough. For a longer transit time or summer temperatures, you can double it. If in doubt, ask our advisers.
How to prevent it: first determine the transport time and the outside temperature. Then calculate the number of gel packs with our calculation formula. Make sure the packs are frozen through completely, see freezing and packing ice packs. Which type suits you, you can read in rigid cooling element or gel pack.
3. Putting ice directly on the product
With meat and fish this is still acceptable, but with pharmaceutical products, chocolate and some foodstuffs, direct contact with ice causes freezing damage. Place ice packs at the side or on top, not underneath or in direct contact.
How to prevent it: put a layer between product and cooling element, for example a piece of cardboard or an inner box. This also works well for products that are sensitive to freezing.
4. Not using an absorbent pad
For fish, meat and plants, an absorbent pad is not a luxury but a necessity. Melting ice and meat juice cause leaking boxes, complaints and damage to your image. A few cents of absorption prevents many euros of damage. View our absorbent pads.
5. Outer packaging that is too light
A cooler box is well insulated on the inside, but the outside has to be sturdy enough for transport. An EPS box without a protective carton can pick up dents during the very first sorting. Always wrap a cardboard outer box or strong tape around it.
Also pay attention to the closure. A lid that does not close properly lets heat in. Tape the box shut all round and check that the lid lies flat.
Three more mistakes we regularly see
- Gel packs that are not fully frozen. A half-frozen pack delivers less cold than you calculate.
- No trial shipment. Test new packaging first with a data logger and look at the temperature curve.
- Forgetting the weekend. Preferably do not ship chilled shipments just before the weekend. A delay at the carrier then costs a lot of cooling time. More seasonal tips can be found in 7 tips for chilled shipping during hot summers.
Checklist for packing
- Box fits the product and is not too roomy
- Gel packs are frozen through completely
- Number of gel packs is calculated for journey time and temperature
- Ice packs do not lie directly on frost-sensitive products
- Absorbent pad is ready for liquid or moisture
- Lid closes properly and the box is taped shut
- Outer packaging is sturdy enough
- Shipping day and delivery date have been checked
Frequently asked questions
How many ice packs do I need?
That depends on the weight of the product, the transport time and the outside temperature. Use the calculation formula as a starting point and check with a trial shipment.
Can I send a chilled shipment without an EPS box?
Yes, there are also other insulation solutions such as insulated bags. What suits best depends on the shipment. See insulated bag or EPS box.
What do I do if my product arrives too warm after all?
First look at the cause. Was the box too large, were the packs not frozen, or did the transport take longer than planned? Adjust one of these points and test again.
Why is a data logger useful?
A data logger records the temperature during transport. You can see when and where the temperature rises and can improve your packaging in a targeted way.
Questions?
Our advisers have worked in practice for years. Visit our contact page for advice that suits your specific shipment.
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