Ice Pack Calculator

Estimate your gel weight

Payload weight (lb), requiredProduct weight only. Enter a number greater than zero.

Inner box size (in), optional

LengthWidthHeight

Enter all three positive dimensions for the volume cross-check, or leave all blank.

Transit timeProduct needsInsulationHottest expected outside tempPack size

ESTIMATE only

Enter your shipment details

Enter a positive payload weight to see an ESTIMATE.

Get a shipping ice pack quote

Placement: start with gel above the payload. For warm or hot routes, test placement along the sides too. Use a barrier where direct contact could damage the product.

Assumptions and sources

These are general planning references and unvalidated adjustments. They are not measured product performance. The tool uses the higher of the payload and volume estimates before applying heat and insulation factors.

How the ESTIMATE is calculated
Input or rule	Method and source
Chilled payload baseline	48 h: approximately one-third of payload weight. IPC cold packs vs. dry ice guidance.
Transit adjustment	ASSUMPTION: 24 h uses two-thirds of the 48 h amount. Same day uses the same amount as 24 h, with no further discount. 72 h uses 1.5 times the 48 h amount.
Volume cross-check	400 g of reference coolant per 5 L at 24 h, doubled at 48 h, from Cooled Solutions guidance. This is a mass-to-volume reference, not a product size offered here. ASSUMPTION: same day uses 24 h; 72 h uses 1.5 times the 48 h reference. Inner box volume includes space occupied by the payload.
Outside heat	ASSUMPTION: under 70°F uses the baseline; 70-90°F multiplies by 1.25; over 90°F multiplies by 1.5. Test these adjustments on your route.
Insulation	ASSUMPTION: EPS under 1.5 inches and insulated liners multiply by 1.3. Thicker EPS uses the baseline. Liner performance varies and this factor is provisional. FedEx perishables guidance recommends foam walls at least 1.5 inches thick and packing for at least 30 hours.
Pack count	Divide the unrounded estimated gel weight in ounces by the selected pack weight and round up to whole packs. Displayed total gel weight is rounded up separately.
Frozen products	No frozen-performance coefficient is available. Any displayed weight remains a chilled baseline. Evaluate a different coolant strategy and test the complete shipment.

How to pack for a test shipment

Condition your product and gel according to their handling instructions. Use an insulated container inside a sturdy outer shipping box.
Begin with gel above the payload. For hotter routes, test additional side placement. Separate coolant from products that could be damaged by direct contact.
Secure the contents against movement and close the insulation fully. Include a temperature logger in a representative product location.
Test the actual route and expected delays. Review the recorded temperatures against your product requirements and revise the pack-out before scaling.

For more context, read our food shipping guide and dry ice shipping guide.

Buyer FAQ

How many ice packs do I need to ship?

Select a pack size to convert the estimated total gel weight into a pack count rounded up to whole packs. This calculator estimates weight from your payload and optionally box volume, then applies assumed transit, heat and insulation adjustments. Validate the pack-out with a temperature logger.

How should I freeze gel packs before packing?

Follow the coolant supplier's conditioning instructions. Allow the gel to freeze throughout, leave room for freezer airflow and confirm conditioning in your pack-out test. This calculator does not set a freezing time.

Should I use gel packs or dry ice for frozen shipments?

This calculator uses a chilled-shipment baseline. Gel alone is likely not enough for frozen shipments over 24 hours. Evaluate dry ice with your packaging supplier and review current carrier acceptance, packaging, marking and documentation rules before booking.

What changes for a hot shipping route?

Use the hottest expected outside temperature along the route, including handling stops. The calculator applies assumed heat factors of 1.25 for 70-90°F and 1.5 above 90°F. These are planning assumptions, not tested performance claims. Test top and side coolant placement under representative route conditions.