Hydropac’s ‘next-gen’ ice pack slashes energy costs and freezing times

Hydropac, a specialist in temperature-controlled packaging, has announced a major technical overhaul of its HydroFreeze ice pack range.

The upgrade is specifically engineered to drive operational efficiency and energy savings for the food and beverage sector as logistics costs continue to squeeze margins.

The primary driver of the new water-based range is a significant reduction in “freeze-down” requirements. Compared to the original HydroFreeze, the new generation is 51% faster to freeze.

For high-volume direct-to-consumer (DTC) brands, this translates to immediate bottom-line impact. A facility conditioning 1,000 packs can now reach optimal temperatures in just six hours rather than twelve. This turnaround speed allows for same-day dispatch and reduces the need for expansive, energy-heavy freezer infrastructure.

Furthermore, the required freeze-down temperature has been adjusted from -30°C to -25°C. This five-degree shift enables suppliers to utilize standard commercial freezing units rather than specialised ultra-low temperature equipment, significantly cutting both capital investment and carbon emissions.

While the new packs freeze faster, they are also engineered to stay cold longer. According to Hydropac’s technical data, the new range offers:

• 110% longer thaw protection compared to previous water-based models.
• 5.2% slower thaw rate than even high-performance gel-based packs.

This extended “thaw-lag” provides a critical safety buffer for “last-mile” delivery, protecting perishable goods against traffic delays, mis-routes, or cold chain breaks that often lead to costly product recalls and food waste.

The upgrade reflects a broader industry move away from gel-based coolants. While gel has traditionally been the standard for performance, Hydropac’s new water-based formula achieves equal or better thermal stability while being significantly easier for the end consumer to dispose of.

“In the demanding world of chilled food logistics, every minute and every degree counts,” said Colin Rowland, managing director at Hydropac. “This upgrade is our answer to the intense pressure our customers face—from ever-tighter delivery schedules to ESG scrutiny.”

By reducing the freeze-down time by 34% overall, Hydropac claims the new range will help companies unlock “working capital savings.” Faster turnover of coolant packs means less stock needs to be held in deep-freeze storage at any given time, freeing up floor space for saleable inventory.

The new HydroFreeze range is available immediately, targeting food brands and retailers looking to modernise their “packhouse-to-doorstep” operations.