Trusted by leading companies
Hard shell ice packs
- Durable HDPE outer shell
- Phase change core cooling
- Reusable and hygienic design
Rugged cooling solutions for demanding cold chain use
When durability meets dependable cooling, hard shell ice packs from Hydropac rise to the occasion. Designed for repeated use, rugged transport conditions, and stringent hygiene requirements, these packs are a robust choice for both chilled and frozen applications. Encased in food-grade HDPE plastic, our hard shell packs resist punctures, leaks, and deformation — even under pressure. Whether used in pharmaceutical shipping, school lunches, or food delivery, they offer consistent performance without compromise. As part of our Ice Packs by Hydropac range, they exemplify our commitment to clean, efficient, and sustainable cold chain solutions — where form, function, and strength go hand in hand.
Discover Hard shell ice packs
Built for the Cold, Made to Last: The Power Behind Hard Shell Ice Packs
When transporting perishable goods or keeping items fresh on the go, the reliability of your cooling system is non-negotiable. That’s where Hydropac’s hard shell ice packs excel — delivering long-lasting performance with unmatched resilience. These aren’t your standard freezer blocks; they’re purpose-engineered for the challenges of modern cold chain logistics.
Why Choose Hard Shell?
Hard shell ice packs offer a superior alternative to basic gel or flexible packs, particularly when strength, hygiene, and temperature consistency matter most. At Hydropac, we take it further by integrating advanced materials, bespoke engineering, and sustainable design principles.
Key Benefits at a Glance
- Rigid HDPE Outer Casing
Crafted from food-grade high-density polyethylene, the shell resists cracks, leaks, and wear — ideal for environments requiring frequent handling. - Phase Change Material (PCM) Core
Inside each pack, you’ll find non-toxic, biodegradable cooling agents with tailored freeze points to maintain stable cold or frozen conditions for hours on end. - Hygienic & Reusable
Easy to clean and sanitise, these ice packs are perfect for pharmaceutical logistics, school lunchboxes, and commercial food delivery systems. - Sustainably Designed
Fully BPA-free, reusable, and recyclable — ticking all the boxes for eco-conscious operations. - Available in Multiple Sizes & Shapes
From compact 200ml units to larger cooling bricks for pallets and containers, our range fits virtually any packaging system.
Trusted Across Critical Sectors
Our hard shell ice packs serve a broad range of clients:
- PharmaPac users trust them to safeguard vaccines, biologics, and lab specimens at specific temperature bands.
- FreshPac clients use them in food-grade coolers and frozen food deliveries, with no risk of cross-contamination.
- Retailers and meal kit providers appreciate their neat form factor, resistance to damage, and consistent cooling over multiple uses.
With decades of expertise behind every design, Hydropac’s hard shell ice packs offer a cooling solution you can trust — again and again. Whether you’re packing fragile medication or frozen treats, our products deliver the protection your items deserve.
Contact us directly
We are ready to answer all your questions and help you find the perfect solution for your cold chain transport.
From issue to a customised cooling solution
In this way we help you to guarantee the quality and safety of food products under all circumstances.
Frequently Asked Questions about Hard Shell Ice Packs
Are hard shell ice packs better than traditional gel packs for frozen food shipments?
Yes. While gel packs are flexible and effective for short-term cooling, hard shell ice packs offer greater durability, thermal stability, and leak resistance. This makes them ideal for frozen food distribution, cold food storage, and courier environments where the packs may be reused and exposed to varying temperatures.
Do Hydropac hard shell ice packs contain Phase Change Materials (PCMs)?
Absolutely. Our PCM-based hard shell ice packs are engineered to freeze and maintain specific cold temperature ranges below 0 °C. This advanced material offers reliable Phase Change Material cooling, which outperforms standard water-based packs in both duration and consistency — perfect for temperature-sensitive products.
What outer materials are used in these ice packs?
Hydropac uses food-grade HDPE plastic for the outer shell. This high-quality plastic is resistant to impact, BPA-free, and compliant with food safety standards. It keeps the internal PCM or gel securely sealed, protecting both the contents and surrounding items during transit.
Are there size options suitable for lunch boxes or compact containers?
Yes. We offer mid-sized and mini options such as the 200ml Mini Gel Ice Brick, designed specifically for school lunches, reusable lunch bags, and compact food containers. Despite their small footprint, these packs maintain powerful cooling capabilities thanks to their PCM core.
Can Hydropac ice packs be customised in shape or design?
They can. Through our Ice Packs by Hydropac range, we offer customised-shaped ice packs for branded food delivery, specialist pharmaceutical needs, and even cryogenic storage applications. Our in-house manufacturing team ensures each shape maintains optimal performance — with no additional tooling fees for bespoke designs.
