Shipping Frozen Food Safely: Cold Chain Guide

Shipping frozen food requires maintaining precise temperatures throughout transit. Here's how to ensure food arrives frozen and safe.

Cold Chain Fundamentals

Temperature Requirements

Food Type	Temperature
Frozen foods	0°F (-18°C) or below
Ice cream	-10°F (-23°C)
Meat/seafood	0°F (-18°C)
Frozen produce	0°F (-18°C)

Cold Chain Components

Production → Packaging → Transport → Delivery → Consumer

Each link must maintain temperature!

Packaging for Frozen Shipping

Insulated Containers

Type	Duration	Cost
Styrofoam cooler	24-48 hours	Low
EPS panels in box	24-48 hours	Low
Reflective liner	24-48 hours	Low
Thick-wall cooler	48-72 hours	Medium
Commercial insulated	72+ hours	High

Refrigerant Options

Refrigerant	Temp	Duration	Notes
Gel packs	Frozen	24-48 hrs	Most common
Dry ice	-109°F	24-72 hrs	Hazmat rules
Phase change	Various	48-72 hrs	Reusable
Frozen water bottles	32°F	24 hrs	For cold, not frozen

Dry Ice Considerations

Benefits:

Coldest option
Sublimates (no liquid)
Long-lasting

Challenges:

Hazmat classification
Carrier limits
Proper ventilation needed
Cannot use for all carriers

Carrier	Dry Ice Allowed?	Limit
USPS	Ground only	5 lbs
UPS	Yes	5.5 lbs (per package)
FedEx	Yes	5.5 lbs (per package)

Carrier Selection

Overnight Services

Carrier	Service	Transit
USPS	Priority Mail Express	1-2 days
UPS	Next Day Air	Next day
FedEx	Priority Overnight	Next day

Cost Considerations

Factor	Impact on Cost
Speed	Faster = higher cost
Weight (incl. packaging)	Major factor
Refrigerant (dry ice)	Adds weight
Box size (insulated)	DIM weight

Packaging Process

Step-by-Step

Pre-freeze everything

Food at 0°F or below
Gel packs fully frozen
Cooler pre-chilled

Layer the bottom

Gel packs or dry ice
Protective layer if using dry ice

Pack food

Vacuum-sealed preferred
Tightly packed
Minimize air gaps

Add top refrigerant

More gel packs
Dry ice on top (cold sinks)

Seal and box

Tape cooler securely
Place in shipping box
Fill gaps

Label appropriately

"Perishable" label
"Keep Frozen"
Dry ice label if applicable

Timing Strategy

Ship Days

Ship Day	Arrival	Weekend Risk
Monday	Tuesday	None
Tuesday	Wednesday	None
Wednesday	Thursday	None
Thursday	Friday	Minimal
Friday	Saturday	High

Best Practice

Ship Monday-Wednesday
Use overnight for weekend arrivals
Check destination weather
Avoid holiday weeks

Food Safety Compliance

FDA Requirements

For commercial food shipping:

Proper food handling license
Cold chain documentation
Traceability records
Appropriate labeling

USDA Requirements

For meat and poultry:

USDA inspection
Proper labeling
Temperature monitoring
Documentation

Monitoring and Tracking

Temperature Indicators

Type	Use
Time-temperature indicators	Shows if temp exceeded
Freeze indicators	Shows if frozen maintained
Data loggers	Continuous monitoring

Why Monitor?

Quality assurance
Liability protection
Customer confidence
Regulatory compliance

Customer Communication

Pre-Purchase

Shipping days available
Transit time expectations
Temperature guarantee
Unboxing instructions

Shipping Notification

Include:

Tracking number
Expected delivery
"Unpack immediately" reminder
Refrigerant disposal info

Unpacking Instructions

Unpack immediately upon arrival
Check temperature (should feel frozen)
Place in freezer right away
If thawed, contact us immediately
Dispose of gel packs or dry ice safely

Handling Issues

If Food Arrives Thawed

Scenario	Resolution
Partially thawed	May be safe (refreeze)
Fully thawed, cold	Check specific food
Warm	Discard, replace

Replacement Policy

Typical policy:

Customer photos required

Temperature at delivery

Replacement shipped next cycle

Or full refund offered

Cost Management

Reducing Costs

Strategy	Savings
Efficient packaging	Less weight
Right-size coolers	Less DIM weight
Gel packs vs dry ice	Cheaper, easier
Regional distribution	Shorter transit
Volume discounts	atoship rates

atoship Frozen Food Shipping

Ship frozen food safely:

Speed filter: Overnight/2-day options

Dry ice compatible: Carriers that accept

Rate comparison: Including heavy packages

Tracking alerts: Real-time monitoring

Insurance: Protect perishable value

Conclusion

Shipping frozen food requires proper insulation, refrigerant, timing, and carrier selection. Use overnight shipping for best results, communicate clearly with customers, and have a replacement policy ready. atoship helps you find the fastest, most affordable shipping options for frozen food.