For a reusable pack, thawing is not damage; even a pack that melts completely on the road goes back into the freezer. Two groups stay out: single-use instant packs that cool through a chemical reaction when squeezed, and packs with a damaged shell. Poison Control advises discarding broken or leaking packs; freezing does not close an opened seam.
Refreezing the pack does not validate the previous shipment. That load's temperature acceptance is decided from its own record, separately from the plate being prepared in the freezer.
Before it goes into the freezer
| Check | What to look for | Outcome |
|---|---|---|
| Identity | Are the model and label readable? | If not, it does not enter prepared stock |
| Shell and seam | Leakage, swelling, an opened cap, lasting distortion | Taken out of use |
| Surface | Soil and moisture | Wiped and dried |
| Arrangement | Air gap between packs | Rack set out accordingly |
GEBHARDT requires the freezer for its eutectic plates to run at least 5 °C below the melting point, an air gap between plates, and the filling to be completely solid before use. The recommended time is 24 hours, varying from 8 to 24 hours with the cooling technology: a -3 °C plate is frozen at -8 °C, a -21 °C plate at -26 °C. Polar Tech, for gel packs of every size and a freezer only 5 °C below the freezing point, advises allowing 24-48 hours for complete freeze-through. The difference between freezing and holding time on the road is covered in at what temperature an ice pack is frozen.
Three stock states are marked separately in the store: returned and awaiting inspection, being prepared in the freezer, and ready for use. The model, entry time and rack position go into the record. That way a newly returned pack that feels cold outside but is still liquid inside does not mix with prepared stock, and counting rejection reasons shows which packs wear out and why.
