HOW-TO GUIDES
Packing Your Temperature-Sensitive Shipments
Quick Reference: 5 Steps to Temperature-Safe Packaging
- Choose the right insulated container sized for your product, refrigerant, and transit time.
- Pre-condition your refrigerant (gel packs frozen solid, dry ice handled with PPE) before pack-out.
- Position the refrigerant based on whether you need to keep contents cold or frozen — top and sides for cold, surrounding for frozen.
- Pack tightly with void-fill so contents don't shift in transit; air gaps reduce thermal performance.
- Seal, label, and ship using a carrier service that matches your required transit window.
💡 Pro tip: The PDFs below are the same field-tested guides our packaging engineers reference. Download and print them for your shipping floor.
📄 Detailed Packing Guides (PDFs)
How to Pack: Choose Materials
Select the right insulated container, refrigerant, and void-fill for your shipment profile.
Five Steps to Temperature-Safe Packaging
Our complete pack-out methodology for keeping products in their target temperature range door-to-door.
Measuring for the Right Fit
Why Measurements Matter
An insulated container that's too large wastes refrigerant; one that's too small compresses your product and reduces thermal performance. The PDFs below give you the exact measuring procedure for each container type.
- Cold packs: Measure outside dimensions when frozen flat — gel pack expansion can shift sizing.
- Foam coolers: Always measure interior cavity, not exterior shell.
- Wine shippers: Bottle diameter and shoulder height determine which insert configuration fits.
📄 Measuring Guides (PDFs)
How to Measure: Cold Packs
Get accurate dimensions for gel packs and rigid cold packs to match your insulated container.
How to Measure: Foam Coolers
Step-by-step procedure for measuring interior dimensions of foam shippers and coolers.
How to Measure: Wine Shippers
Match bottle profiles to the right wine shipper insert configuration with our sizing chart.
Gel Pack Conditioning & Usage
Conditioning Your Gel Packs
Proper conditioning is the difference between a successful temperature-controlled shipment and a failed one. Follow these steps every time:
- Lay packs flat in a freezer at 0°F (-18°C) or colder. Stacking too deeply slows the freeze.
- Allow 24–48 hours for full conditioning. Time depends on pack size and freezer load.
- Verify they're solid before use — any slosh means they're not fully conditioned.
- Use immediately after removing from the freezer for maximum cold reserve.
Refrigerated vs. Frozen Shipments
- Refrigerated (35–46°F / 2–8°C): Use gel packs conditioned to refrigerator temperature OR partially-thawed frozen packs to avoid product freezing.
- Frozen (below 32°F / 0°C): Use fully frozen gel packs OR dry ice for deep-frozen shipments.
- Layer placement matters: Separate gel packs from product with a thin barrier when shipping refrigerated to prevent freeze damage.
💡 Need testing? Our in-house thermal lab can validate your specific pack-out configuration. Request a test →
Recycling & Disposal Guidelines
General Recycling Notes
Polar Tech products are designed with end-of-life in mind, but recycling options vary by material and locality. The PDFs below have specific instructions for each product type.
- Gel packs: Contents are non-toxic and can be safely emptied into household trash. The plastic film is recyclable in many curbside programs.
- Rigid foam cold packs: Contact your local recycler — some accept these as #6 polystyrene.
- Foam coolers (EPS): Many local programs and drop-off locations accept clean foam. Check Earth911 or your municipality.
📄 Disposal Guides (PDFs)
How to Recycle: Gel Cold Packs
Safe disposal procedure for gel-filled cold packs and the recyclable plastic film.
How to Recycle: Rigid Foam Cold Packs
Disposal and recycling guidance for solid foam cold packs (RB series).
How to Recycle: Foam Coolers
EPS foam cooler recycling options, drop-off locations, and reuse suggestions.
📚 Popular Resources
🧪 Testing Services
Validate your pack-out with our in-house thermal testing lab. Get formal reports and optimization guidance.