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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.

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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

For foods within the scope of the EU Directive on quick-frozen foodstuffs, the general requirement is –18 °C or colder at all points in the product. The permitted brief temperature deviations during transport are not a basis for routinely shipping at higher temperatures.[F1]

Edible ices are explicitly excluded from this Directive but remain subject to the applicable requirements. The relevant product and transport specifications must therefore be considered for ice cream and other edible ices, frozen pet food and specialist recipes.[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.

[F3][F4]

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.
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Dry ice

Dry ice can be used in suitable EPS and paper insulated boxes. Preparing the shipment also involves sourcing the coolant, accounting for CO₂ release and planning how the recipient will handle any remaining dry ice.[F5][F4][F6]

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

Pre-cooling, order quantities and transit time

  1. 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.

  2. 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.

  3. 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.

  4. 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 boxes and bags

EPS and paper packaging for frozen goods

EPS insulated boxes and Basic / Pro paper insulated boxes can be combined with coolants for frozen shipping. Size selection allows space for the goods, coolants and necessary separation. The achievable transit time depends on the complete packout and cannot be determined from wall thickness alone.

For smaller shipments without dry ice, Paper Bag can be tested with suitable coolants. Even with small quantities, the combination must maintain the required product temperature throughout transit.

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Insulated box sizes and configurations →
Basic and Pro paper insulated boxes →
Paper insulated bags for smaller shipments →

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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Have your thermal packout tested ↗
Thermal engineering and temperature testing →

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 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.

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Other applications: Food and pet food at a glance.

Technical sources & further information

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

  1. 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.
  2. Regulation (EU) 142/2011 on animal by-productsA separate EU regulatory framework for animal by-products and pet food.
  3. 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.
  4. Dry ice: carbon dioxide poisoning is possible – Opinion 047/2020Carbon dioxide release, ventilation and handling dry ice.
  5. Insulated boxes for passive temperature-controlled transportTHERMOCON’s range and the application limits of its insulated boxes, including Paper Bag.
  6. Shipping dry iceOne carrier’s requirements; check the conditions of the carrier actually engaged.
  7. Paper-based insulated boxesProduct characteristics of Basic and Pro paper insulated boxes.
  8. Paper insulated bags for chilled shippingProduct characteristics and coolant configuration of the paper insulated bag.
  9. Thermal engineeringDevelopment and thermal testing of defined packouts.

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