Frozen food shipping

Insulated packaging for frozen food and frozen pet food

THERMOCON helps you choose insulated boxes and coolants for frozen food and pet food. The key factors are your products’ temperature requirements, their condition at packing and the time until receipt. Varying order quantities and potential delays are also taken into account.

Open EPS insulated box with its lid standing separately — EPS insulated box as the insulating component. The coolants and packout are defined for the goods, transit time and permitted product temperature.

Temperature requirements

Temperature requirements for quick-frozen products

Set the frozen-product temperature from the applicable US requirements and product specification. For EU-bound foods within the EU Directive on quick-frozen foodstuffs, the general requirement is –18 °C or colder throughout the product. Its permitted brief transport deviations do not justify routine shipping above that limit. The EU Directive does not establish a blanket temperature rule for all US frozen shipments.^[F1]

Ice cream and other edible ices are excluded from that EU Directive but remain subject to applicable product requirements. For US frozen food, frozen pet food and specialty recipes, establish the appropriate temperature and transport specification for the actual product. FDA animal food requirements apply within their respective US scope.^[F1]^[F2]

Coolants

PCM coolants and dry ice compared

PCM coolants contain a material that absorbs heat as it melts. Frozen-shipping coolant packs are frozen before packing according to the product instructions. With dry ice, you also need to plan for sourcing, ventilation and the recipient’s handling of any remaining dry ice.

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PCM coolants for frozen shipping

THERMOCON offers PCM coolants with a melting point of −21 °C as gel packs, Foam Bricks and rigid coolant packs. The suitable format depends, among other factors, on the space inside the box and whether single or repeated use is planned. The −21 °C value describes the coolant. How cold the goods remain and how long protection lasts are tested with the loaded box.^[F3]

Check whether your freezing equipment reaches the temperature specified for the chosen coolant and whether enough packs can be prepared in time.
The number and arrangement of coolant packs must suit the smallest and largest planned orders.
Enough space must remain for the goods after the coolants and separating layers are in place.

Dry ice

Dry ice can be used in suitable EPS insulated shippers in the US range. Preparing the shipment includes sourcing dry ice, allowing for CO₂ release and planning how the recipient will handle any remaining coolant. For a pre-qualified dry ice configuration, compare the payload and conditions on the US Dry Ice Line page.^[F5]^[F4]^[F6]

The shipment must meet the carrier’s acceptance conditions for the relevant mode of transport.
Marking, labeling, documentation and required training must be established before shipping.
The recipient must be prepared to receive and handle the shipment safely.

Shipping process

Pre-cooling, order quantities and transit time

Temperature before packing
What matters is the actual temperature of the goods when they are packed. Include time outside frozen storage: picking, packing and waiting for collection. These steps must be included when defining the protection time required.
Smallest and largest orders
Individual portion bags and larger orders may need different packaging. Alongside minimum and maximum payloads, intermediate quantities are considered when they change the positions of the goods or coolants.
Transit time including delays
The relevant period extends from packing through collection and depot handling to receipt of the goods. Foreseeable delays, such as another delivery attempt or a weekend, are also included. The additional time allowance needed is defined before testing.
Packing instruction for daily shipping
The packing instruction records the product quantity, coolants, preparation, arrangement and closure. It also describes which changes require reassessment, such as a different carton or a new bag format.

Insulated shippers and coolant packs

EPS packaging for frozen goods

EPS insulated shippers can be combined with suitable coolants for frozen shipping. Allow space for the goods, coolant and necessary separation. The achievable shipping duration depends on the complete packout and cannot be determined from wall thickness alone. Dry Ice Line provides defined dry ice configurations for comparison with your requirements.

For smaller shipments without dry ice, evaluate an EPS shipper with appropriate PCM coolant packs. Even with small payloads, the combination must maintain the required product temperature throughout shipping.

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Thermal testing

Temperature testing of the complete insulated packout

Temperature testing considers, among other factors, your smallest and largest planned shipments. The packaging is packed with defined product and coolant temperatures and exposed to the agreed ambient temperature profile. The report shows how the temperature changes at the selected measurement positions throughout the test.

Before a test, we agree with you which packaging sizes, payloads and transit times to investigate. This establishes which results your shipping and quality assurance teams need for selection.

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Questions about frozen shipping

Questions about coolants and transport conditions

How much dry ice is needed per parcel?

The quantity required depends on the goods, box, starting temperatures and transport conditions. The longest planned transit time and potential waiting times therefore also matter for the calculation. The resulting configuration is then tested.

Can packaging containing dry ice be sealed airtight?

The packaging must allow the CO₂ released by dry ice to escape. Adequate ventilation is also required. Packaging and shipping must additionally meet the requirements of the relevant mode of transport and the chosen carrier.^[F4]^[F6]

Does dry ice remaining on arrival prove that the cold chain was maintained?

No. Remaining dry ice does not show the temperatures experienced by the goods during transport. This requires temperature measurements at suitable positions in the shipment. Remaining coolant alone therefore cannot confirm that the cold chain was maintained.

Can frozen and chilled products be shipped together?

A combined shipment must meet the temperature requirements of both product groups. This requires suitable separation and testing of the complete packout. Additional coolant packs alone do not resolve this question.

How is an extra day before delivery accounted for?

The conditions during the delay are defined for the packaging test. A temperature-controlled interim storage facility places different demands on the packaging from a depot without temperature control. Both the duration and ambient temperature of that extra day are included in testing.^[F9]

THERMOCON USA advice

Advice on insulated packaging for your frozen products

With details of the product type, required temperature, smallest and largest shipments, transit time and destination countries, we can help you select suitable packaging. Also let us know whether you already use dry ice or would like to assess an alternative.

Technical sources & further information

Last reviewed: November 1, 2026. The current product specification and the requirements applicable to the shipment remain authoritative.

Directive 89/108/EEC on quick-frozen foodstuffs, version of 01.07.2013Articles 1 and 5: EU scope of application, product temperature and explicitly excluded edible ices.
FDA: requirements for animal food businessesUS animal food requirements, including sanitary transportation where applicable.
THERMOCON frozen-shipping coolants: gel pack, Foam Brick and rigid coolant packThree formats with a PCM melting point of −21 °C; coolant selection and preparation.
Dry ice: carbon dioxide poisoning is possible – Opinion 047/2020Carbon dioxide release, ventilation and handling dry ice.
EPS insulated shippers for passive temperature-controlled transportTHERMOCON US shipper range and product-specific configuration requirements.
FedEx US: shipping with dry iceCarrier-specific packaging, marking and acceptance conditions; confirm the requirements of the chosen service.
Foam BricksUS coolant formats for defined packouts, including frozen-shipping options.
Gel packs for cold chain shippingUS gel pack formats and preparation for the complete shipping configuration.
Thermal engineeringDevelopment and thermal testing of defined packouts.

Systems

Product lines

Coolant Packs

Coolant pack types

EPS Shippers