Meal kit packaging is about something different from most chilled shipments: not the heaviest insulation, but the lowest cost price per order for a handling operation repeated hundreds of times a day. This page is intended for meal kit providers, fresh food delivery companies and fulfilment partners who do their own purchasing. Cooled Solutions has been producing cooling packaging in-house since 1972.
The difference from other chilled shipments
A meal kit is almost always a shipment of 24 hours or less, with a known route and a known delivery day. That means you do not need to over-specify as you would for pharma or frozen goods. What you do steer on: the number of handling operations per order, the volume in your warehouse and the shipping costs per parcel.
Two routes
| Route | Set-up | Strength |
|---|---|---|
| Insulated bag in your own box | 2-ply insulated bag with adhesive strip, plus ice pack sheets | flat in storage, no second box type, closes without tape |
| Ready-made cooling box | Thin-walled polystyrene (EPS) box with ice pack sheets | one handling operation, sturdy, no folding |
For most meal kit providers, the insulated bag is the most economical route: one bag per order keeps the number of handling operations low, and the bags lie flat in the warehouse instead of taking up space as empty boxes. The 35×55 cm size is the most commonly used for this. The 2-ply version is available in 25×35, 30×45, 35×35, 35×55, 67×52 and 70×70 cm.
If you prefer a box rather than a bag, the thin-walled polystyrene version is the equivalent: sufficient for 24 hours, light on shipping costs.
Coolant: flat works better than block-shaped
In a meal kit, the products lie in layers. Ice pack sheets follow that shape: they cool flat across the entire surface instead of at a single point, and take up hardly any height. You fill them with water and freeze them yourself, which keeps purchasing costs and inbound transport weight low.
- Place the coolant on top of the meals: cold air sinks and cools the entire contents evenly.
- Freeze the coolant for at least 24 hours at −18 °C before packing.
- Fill up empty space. A half-full box takes more cooling than a full one.
Also see the full range of coolants.
Which set-up for which transit time
| Transit time | Set-up | Example |
|---|---|---|
| Up to 24 hours | Cooling box or insulated bag with coolant | 2-ply insulated bag 35×55 cm with ice pack sheets, or thin-walled EPS |
| 24 to 48 hours | Extra insulation and more coolant | 4-ply insulated box liner with gel packs |
If the box contains meat or fish, apply the strictest requirement of the box: chilled at 2 to 8 °C.
Sustainability
If you want outer packaging that is fully recyclable as paper, cardboard cooling boxes are the alternative. For brands that lead with sustainability, that is often a deliberate choice; bear in mind that the cost price per order is higher than with an insulated bag.
Regular volume purchasing
Meal kit providers consume at volume by definition. Ordering by the pallet is considerably cheaper than by the outer carton, and fixed-rate annual contracts are possible for regular buyers. We produce custom sizes to order with a lead time of 2 to 4 weeks, and private label, your own branding on the packaging, or fully neutral, is possible. Also see the selection for e-commerce or request a quote with your size and annual volume.
Frequently asked questions
What is the most economical packaging for a meal kit?
For most providers, a 2-ply insulated bag with adhesive strip inside your own cardboard box, combined with ice pack sheets. One bag per order keeps the number of handling operations low and the bags lie flat in the warehouse.
Which insulated bag size suits a meal kit?
35×55 cm is the most commonly used size. The 2-ply version is also available in 25×35, 30×45, 35×35, 67×52 and 70×70 cm.
Why ice pack sheets and not regular gel packs?
Meals lie in layers. Sheets cool flat across the entire surface instead of at a single point and take up hardly any height. You fill them with water and freeze them yourself.
Is a 24-hour meal kit sufficiently cooled with a single bag?
For a shipment of up to 24 hours, a 2-ply insulated bag with coolant is sufficient, provided the coolant is frozen solid and placed on top. In high outdoor temperatures, scale up the coolant.
Can the packaging carry my own brand?
Yes. Private label is possible: your own branding on the packaging, or delivered fully neutral.