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Innovations in Food-Safe Gel Ice Packs

Innovations in Food-Safe Gel Ice Packs

Published On: September 28, 2024 Revised On: October 5, 2024

Over the next decade, the global cold-chain packaging refrigerants market – gel ice packs and liners included – is projected to double. Towards Packaging estimates that it will grow from $1.61 billion in 2022 to a promising $3.36 billion by 2032.

As of 2022, the Asia Pacific region played a pivotal role, holding an estimated 30% market share, rivalling North America’s 31%. The region’s growth of e-commerce, online grocery services, and global food and pharmaceutical logistics is a central growth driver.

As a result, there has been a global surge and demand for more efficient and sustainable cold-chain packaging solutions. Innovations in food-safe gel ice packs, integral to temperature-controlled shipping, are making an impact. However, the entire cold chain is seeing improvements. Changes aimed at reducing environmental impact, energy usage, and waste also result in operational savings for businesses.

6 Innovations in Gel Ice Packs and Sustainable Cold Chain Packaging

Food-safe gel ice packs preserve packaged foods and medicines during transit, resulting in a reduction in spoilage and food waste. However, steps are being taken to make these items even more effective and eco-friendly.

Other cold chain packaging solutions that reduce wastage, such as thermal liners, insulator bags, and condensation sheets, are also having improvements in their technology.

Reusable and Non-Toxic Ice Packs

A growing trend in the cold chain industry is the development of reusable and non-toxic ice packs. Reusable gel ice packs can be re-frozen and reused multiple times, making them both most-effective and environmentally friendly.

Naturally, a key aspect of this process involves reusing the gel ice packs. Misfits Market has introduced a strategy to collect its packaging materials, including ice packs and LDPE liners. So far, this initiative has significantly reduced the company’s waste, reclaiming over 9.3 million pounds for reuse or recycling.

Phasing Out Hydrofluorocarbons In Refrigeration

One of the other environmental issues surrounding cold chain packaging and shipping is refrigeration. Products are refrigerated before, during, and after shipping with the packaging.

Gel ice packs need to be frozen solid before they are used and this requires energy from the freezer equipment. Hydrofluorocarbons, or HFCs, as they’re commonly known, are synthetic gases predominantly used in refrigeration and cooling appliances.

It’s estimated that the refrigeration sector contributes to 20% of global hydrofluorocarbon usage. HFCs are estimated to make up around 2% of all global greenhouse gases. HFCs possess a warming potential hundreds to thousands of times greater than that of carbon dioxide, making even small percentages consequential for global warming.

However, there is reason for optimism. With growing attention on sustainability, many countries and companies are focusing on phasing out HFCs by 2050. This step follows the successful elimination of other ozone-depleting substances over the last few decades that HFCs initially replaced.

Minimizing Refrigeration Times

Many businesses and organisations are looking at ways of optimising refrigeration times to reduce energy usage, emissions, and costs. KPS Global, a leader in industrial and commercial freezer and refrigeration solutions, developed the Arctic Express Gel Pack production system.

It can be installed on-site and freezes gel ice packs in at least 45 minutes. Usually, a pallet of around 1,800 gel ice packs would take up to 2 and a half weeks to freeze. This system – which won the Bronze in the 2021 Edison Awards in the Manufacturing, Logistics & Transportation category – has saved some customers money, as refrigeration times are much shorter.

It has also reduced the carbon emissions of some customers by up to 97%. Installing more energy-efficient coolers and freezers is an ideal way to reduce refrigeration times, lowering costs and your carbon footprint. As such, there is an increased demand for these energy-efficient systems.

Rightsizing and Tailored Packaging Approaches

Businesses are also optimising their packaging process to reduce waste. Misfits Market has taken a rightsizing approach to reduce its packaging waste. The company uses an algorithm to decide the perfect amount of packaging required to maintain food integrity.

Since they re-collect a large percentage of gel ice packs and other cold chain packaging, this approach also streamlines its transport operations. Additionally, HelloFresh has developed a region-specific, seasonally adjusted packaging solution designed to minimise waste, further contributing to sustainability efforts.

It ensures packages are insulated according to accurate weather predictions and climate – not generically, which results in unnecessary packaging waste. Using such software, tools, and processes dedicated to reducing waste, other businesses can also achieve sustainability and cost-cutting targets.

Another area of innovation is intelligent packaging, which incorporates sensors to monitor temperature, gas composition, and bacterial growth during shipping. This technology ensures that goods remain within the required temperature range, enhancing both food safety and the efficiency of the cold chain.

Sustainable Packaging Solutions

Companies are also innovating by formulating more sustainable packaging. In its Packaging Lab, Hello Fresh works on creating more sustainable and financially viable packaging solutions for its business. It has developed a Paper Pouch, which is made from recycled paper that insulates package contents.

Another innovation is its 100% recyclable water-based ice pack. While more biodegradable, water-based ice packs aren’t always recyclable and are less effective than gel-based ones in terms of cooling duration. However, companies and packaging manufacturers are exploring ways to combine the benefits of gel ice packs with greener materials.

Industrial Guidelines and Standards

Adhering to established industrial guidelines and standards is essential for ensuring both quality and sustainability in gel ice packs and cold chain packaging. Compliance with standards like ISO 9001 for quality management and ISO 14001 for environmental management helps maintain high production standards while minimising environmental impact.

In the cold chain industry, frameworks such as Good Distribution Practices (GDP) and Good Manufacturing Practices (GMP) ensure the safe and efficient handling of temperature-sensitive products. Additionally, the use of recyclable materials and non-toxic gel formulations, in line with regulatory requirements like the European Union’s REACH regulation and the U.S. Food and Drug Administration (FDA) guidelines, enhances product safety and sustainability efforts.

Regulation	Description
ISO 9001	A quality management system standard that ensures consistent quality in production and services.
ISO 14001	An environmental management system standard that helps organizations reduce their environmental impact.
Good Distribution Practices (GDP)	Framework for ensuring that products are consistently stored, transported, and distributed under proper conditions.
Good Manufacturing Practices (GMP)	Guidelines that ensure products are consistently produced and controlled according to quality standards.
European Union REACH regulation	Regulation aimed at improving the protection of human health and the environment from risks posed by chemicals.
U.S. Food and Drug Administration (FDA)	Regulatory agency responsible for protecting public health by ensuring the safety, efficacy, and security of food, drugs, and other products.

Conclusion

As the cold chain packaging industry continues to evolve, innovations in food-safe gel ice packs and other essential packaging items will continue. These improvements are crucial in increasing efficiency and reducing environmental impact, waste, and costs.

By embracing sustainable solutions, recycling, reusing, and optimizing its cold chain, the industry is making significant strides. With continued investment in research and development, we can expect even more advanced packaging technologies to emerge, further enhancing the sustainability and effectiveness of cold chain logistics.

At Humi Pak, we offer a comprehensive range of cold chain packaging solutions, including our Ice Peak gel ice packs. These ice gel packs are food-safe, reusable, non-toxic, and manufactured in accordance with the stringent requirements of ISO 9001 and ISO 14001 standards. Feel free to contact our packaging engineers to learn more about our solutions.