Chilled Packaging Mistakes and How to Avoid Them
With temperature-sensitive shipping, chilled packaging is mission-critical. Whether you're
delivering fresh food, pharmaceuticals, or lab samples, the right cold chain solution ensures products stay safe, compliant, and high-quality from dispatch to delivery. Yet, many businesses overlook key details that can make or break their cold chain performance.
In this blog, we outline the top chilled packaging mistakes companies make and provide actionable guidance to help you avoid them. Mastering these principles will protect your goods, reduce spoilage, and boost customer satisfaction.
Choosing the Wrong Insulating Material
Not all packaging materials are created equal. Many businesses make the mistake of choosing liners or insulation that aren't designed for their specific shipping conditions.
❌ Common Errors:
● Using basic foam or bubble wrap with no thermal barrier
● Opting for metallised polymer film instead of true aluminium foil
● Choosing low-grade wool or cotton without thermal testing
📅 How to Avoid It:
● Match the insulation type (foil, wool, foam, etc.) to your transit time and temperature range.
● Use materials with proven thermal test data.
● Consider dual-layer systems for longer durations.
🔹 Pro Tip: Foil liners are great for short-term shipping (24-48 hours), while wool liners offer extended insulation (48-96+ hours).
Underestimating the Role of Proper Sealing
You can use the best materials in the world, but if your packaging isn’t properly sealed, cold air escapes and warm air creeps in.
❌ Common Errors:
● Leaving air gaps in box liners
● Not fully closing insulated envelopes or pouches
● Using boxes that are too large, causing movement and temperature loss
📅 How to Avoid It:
● Use snug-fit packaging to eliminate dead space.
● Seal liners and boxes securely with strong adhesive tape.
● Train staff on consistent packing techniques.
🔹 Pro Tip: Always conduct a final inspection for air gaps or loose corners before dispatch.
Skipping Pre-Conditioning of Gel Packs or Ice Pads
Chilled packaging isn’t plug-and-play. If you don’t properly freeze your gel packs or ice pads before use, your cold chain will fail quickly.
❌ Common Errors:
● Freezing gel packs for too short a time
● Using refrigerants straight from a freezer without temperature stabilisation
● Storing gel packs in variable-temperature environments
📅 How to Avoid It:
● Follow manufacturer instructions (typically 24-48 hours of freezing at -18°C or below).
● Pre-condition refrigerants to match the product's required temp (e.g., chilled, frozen).
● Store packs in commercial freezers, not household units.
🔹 Pro Tip: Use phase change materials (PCMs) if precise temperatures (e.g., 2°C-8°C) are required.
Failing to Test Packaging Systems in Real-World Conditions
It’s easy to assume your packaging works, but without real-world testing, you’re flying blind. Temperature data loggers are inexpensive compared to the cost of a failed delivery.
❌ Common Errors:
● Relying only on supplier specs
● Not conducting route-specific validation tests
● Ignoring extreme weather scenarios
📅 How to Avoid It:
● Run trial shipments with temperature loggers to collect real performance data.
● Simulate worst-case conditions (e.g., delays, outdoor storage).
● Re-test seasonally or when changing logistics partners.
🔹 Pro Tip: Document your validation results for compliance with food safety or pharma regulations.
Using Inappropriate Box Sizes
Thermal performance is compromised when boxes are too large for their contents. Dead space leads to airflow, temperature inconsistencies, and wasted refrigerants.
❌ Common Errors:
● One-size-fits-all approach to cartons
● Leaving voids that aren’t filled with insulation or dunnage
📅 How to Avoid It:
● Use packaging that fits your products snugly.
● Choose modular systems that scale with product volume.
● Add void fillers or extra insulation to eliminate space.
🔹 Pro Tip: Compact packaging also saves on courier costs.
Ignoring Labelling and Handling Instructions
Even if your packaging is perfect, mishandling during transit can ruin everything. Improper labelling is a leading cause of damaged cold chain shipments.
❌ Common Errors:
● No "Perishable" or "Keep Refrigerated" labels
● Not informing logistics providers of special handling requirements
● Assuming carriers will know how to treat cold chain parcels
📅 How to Avoid It:
● Use bold, weather-resistant labels on multiple sides of the box.
● Include temperature range indicators.
● Communicate clearly with couriers and partners.
🔹 Pro Tip: Use smart labels with temperature indicators for added security and customer confidence.
Overlooking Sustainability and Customer Expectations
Consumers and business clients alike are demanding greener solutions. Many companies lose customer trust by using non-recyclable or excessive packaging.
❌ Common Errors:
● Relying on single-use plastics
● Not offering disposal instructions
● Choosing performance over sustainability without balance
📅 How to Avoid It:
● Switch to eco-friendly liners like true aluminium foil or EoWool.
● Educate your customers on how to recycle or return packaging.
● Choose suppliers with clear sustainability credentials.
🔹 Pro Tip: Highlight your green packaging initiatives on your website and boxes to build brand loyalty.
Not Keeping Up with Regulations and Standards
Industries like pharma, biotech, and food are tightly regulated. Non-compliance can lead to fines, product recalls, and reputational damage.
❌ Common Errors:
● Outdated knowledge of cold chain requirements
● No documentation of packaging performance
● Assuming generic packaging meets industry-specific standards
📅 How to Avoid It:
● Stay informed about updates to GDP, HACCP, ISO, and other regulations.
● Work with suppliers who provide certified thermal packaging solutions.
● Keep thorough records of validation and performance testing.
Conclusion: Excellence in Chilled Packaging Is in the Details
Cold chain packaging isn’t just about keeping things cold—it’s about maintaining a controlled environment, building trust with customers, and ensuring regulatory compliance. Small mistakes in materials, training, or planning can lead to big problems.
By avoiding these common pitfalls and following best practices, your business can:
● Reduce spoilage and returns
● Improve customer satisfaction
● Stay compliant with food and pharma safety standards
● Cut unnecessary costs from shipping inefficiencies
Need help reviewing or upgrading your chilled packaging systems? Contact our cold chain
experts today for tailored advice and high-performance, eco-friendly packaging solutions that protect your products and your brand.
For innovative and eco-conscious chilled packaging solutions like EcoWool, Thermapack-Box, CoolaGels, and CoolaPacks, check out our website.