frozen-fooddry-icecold-chain
Cheapest Way to Ship Frozen Food (Dry Ice Guide)
Shipping frozen food requires special handling. Learn about dry ice, insulated packaging, and the most affordable options.
January 9, 20264 min read32 views
Frozen Food Shipping Basics
Frozen food shipping is complex:
- Temperature must stay frozen
- Dry ice has carrier restrictions
- Speed is critical
- Packaging is specialized
The Cold Chain Challenge
Temperature Requirements:
| Food Type | Max Temp | Duration Challenge |
|---|---|---|
| Frozen meat | 0°F | 24-48 hrs |
| Ice cream | -20°F | Very difficult |
| Frozen seafood | 0°F | 24-48 hrs |
| Frozen produce | 0°F | 24-48 hrs |
Dry Ice Basics
What It Is: Frozen CO2 (-109°F), sublimates directly to gas
Carrier Rules:
| Carrier | Dry Ice Limit | Requirements |
|---|---|---|
| USPS | 5 lbs | Hazmat label, no Priority Express |
| UPS | 5.5 lbs (ground), 200 lbs (air) | UN3373 label |
| FedEx | 200 lbs | Dangerous goods declaration |
- Standard cooler: 5-10 lbs/day
- Insulated shipper: 3-5 lbs/day
Packaging for Frozen Food
Components Needed:
Cost Breakdown:
| Component | Cost |
|---|---|
| Insulated shipper | $5-15 |
| Dry ice (5 lbs) | $3-5 |
| Outer box | $2-4 |
| Gel packs (reusable) | $2-5 |
| Total packaging | $12-29 |
Shipping Service Options
Overnight (Best for Frozen):
| Carrier | Service | Rate (5 lb, Zone 5) |
|---|---|---|
| UPS Next Day Air | Overnight | $85+ |
| FedEx Priority Overnight | Overnight | $82+ |
| USPS Priority Express | 1-2 days | $42+ |
| Carrier | Service | Rate |
|---|---|---|
| UPS 2nd Day Air | 2 days | $45+ |
| FedEx 2Day | 2 days | $42+ |
- Only for nearby zones (1-2)
- Only in winter
- Very risky
Cheapest Frozen Food Options
Strategy 1: Ship Early Week
- Ship Monday/Tuesday
- Avoid weekend sitting in warehouse
- Reduces dry ice needed
- Only offer to zones 1-3
- 1-2 day ground delivery
- Cheaper than air
- Cheapest overnight-ish option
- 1-2 day delivery
- $42+ vs $80+ for UPS/FedEx
Dry Ice Quantity Guide
| Transit Time | Dry Ice Needed |
|---|---|
| Overnight | 5-7 lbs |
| 2-day | 10-15 lbs |
| 3-day (risky) | 20+ lbs |
Gel Packs vs Dry Ice
Gel Packs:
- For "cold" not "frozen"
- No carrier restrictions
- Reusable
- Won't keep items frozen long
- Keeps items frozen
- Has carrier restrictions
- Sublimates (disappears)
- Requires ventilated packaging
Cost Comparison: 5 lb Frozen Package, Zone 4
| Option | Packaging | Shipping | Total |
|---|---|---|---|
| UPS Next Day | $15 | $75 | $90 |
| FedEx Overnight | $15 | $72 | $87 |
| USPS Priority Express | $15 | $38 | $53 |
| UPS 2-Day (risky) | $20 | $42 | $62 |
Labeling Requirements
Dry Ice Shipments:
- "Dry Ice" or "Carbon Dioxide, Solid"
- UN1845
- Weight of dry ice
- Hazmat diamond (Class 9)
- "Perishable" label
- "Keep Frozen" label
- "This Side Up" arrow
Reducing Frozen Shipping Costs
Winter vs Summer
Winter Advantage:
- External temps help
- Less dry ice needed
- Ground shipping may work
- More dry ice required
- Overnight only recommended
- Higher packaging costs
Action Steps
Ship frozen food successfully with the right planning and Atoship's competitive overnight rates.
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