Shipping meal boxes chilled: what do you need?
Short answer: for a meal kit box, you need: a 30–45 liter EPS or honeycomb insulated box, gel packs above meat and fish (cold air sinks), an absorbent mat on the bottom, and dividers so vegetables and herbs do not touch the cold packs directly (frost damage). This keeps a mixed box at the right temperature for 24–48 hours.
Meal kit companies and meal box providers are a fast-growing sector. Fresh ingredients, meat, fish, dairy — everything must arrive at the customer perfectly fresh, often after 24 to 48 hours in transit.
The challenge
You ship a complete meal kit box with various temperature-sensitive components:
- Fresh meat or fish (0-4 °C)
- Dairy products (4-7 °C)
- Fresh herbs and vegetables
- Sometimes also dry ingredients at room temperature
Everything in one package, for at least 24 hours of transport, often in summer conditions. This requires a well-thought-out approach.
The ideal combination
1. Outer packaging: EPS box or honeycomb insulated box
For an average meal kit, we recommend a 30-45 liter EPS or honeycomb box. Honeycomb has an appealing environmentally friendly look that suits many meal kit brands.
2. Cooling agents: gel packs in the right place
- Fresh fish/meat: gel packs directly above (cold air sinks)
- Dairy: gel pack next to it
- Vegetables/herbs: not directly against cold packs (frost damage)
3. Absorbent mat on the bottom
Any meltwater or liquid is absorbed — preventing wet products and leaking boxes.
4. Separating materials
Use cardboard or plastic dividers to separate sensitive products from the cooling elements.
Cost optimization
Meal kit margins are often tight. Tips for saving costs:
- Order packaging by the pallet for economies of scale
- Standardize on 1-2 box sizes instead of 5
- Reuse gel packs (some providers do this with a return system)
- Request a quote for an annual contract
For meal kit companies, Cooled Solutions offers:
- Fixed price agreements for volume orders
- Combination pallets with various products
- Ordering on account (Net 30)
- Custom printing of insulated boxes available
- Fast delivery from stock
Request a tailored quote for your meal kit business.
Order now
Need the right packaging immediately? View our EPS boxes, gel packs, insulated envelopes and cold chain packaging for e-commerce.
