Shipping chilled meat requires a heavier setup than most chilled products. Meat must never leave the cold chain, and a shipment that goes over the limit even once cannot be recovered. This page describes which setup suits which transit time, how much coolant you need and where most mistakes are made. Cooled Solutions has been producing cold chain packaging in-house since 1972.
Which setup for which transit time
Work with the longest realistic time to arrival, including possible delays or a weekend in between. A shipment that leaves on Friday and arrives on Monday is a 72-hour shipment.
| Transit time | Setup | Example |
|---|---|---|
| Up to 24 hours | Thick-walled insulated box with coolant | EPS box with thick walls and 2 to 3 gel packs |
| 24 to 48 hours | Extra insulation and more coolant | 4-layer insulated box liner with ice packs |
| 48 to 72 hours | Maximum insulation and generous cooling | 6-layer insulated box liner or EPP with plenty of ice packs |
For an online butcher with next-day delivery, the first row is the standard: a thick-walled polystyrene box with 2 to 3 gel packs. The thick wall is deliberate here: for meat you do not choose the lightest box that only just makes it, but the box that also absorbs a delay.
Temperature zones
| Zone | Temperature | Product | Coolant |
|---|---|---|---|
| Chilled | 2 to 8 °C | fresh meat, poultry, cold cuts | gel packs or ice packs |
| Frozen | below −18 °C | frozen meat | plenty of ice packs, by arrangement |
Torn between two zones? Stick to the coldest requirement.
Frozen versus chilled
Frozen meat calls for more cooling mass and thick-walled packaging, even on shorter runs. For shipments of 24 to 48 hours, combine a thick-walled version with plenty of ice packs. If in doubt about the setup, our specialists will do the sums with you: for frozen goods, a wrong estimate costs more than the packaging itself.
Meltwater and hygiene
EPS absorbs no moisture or odour and is suitable for contact with foodstuffs. If you work with thawing product that releases moisture, there is a version with drainage holes that lets the moisture escape. If you ship via a parcel carrier, choose a closed version instead: leakage onto other parcels is not acceptable there.
Shipping in your own box
If you already have a standard cardboard shipping box, there is no need to buy a second type of box. An insulated box liner turns that box into chilled packaging, stores flat and is light on shipping costs. For one-day deliveries the 2-layer version with self-adhesive strip is sufficient; for longer transit or warm periods, choose 4- or 6-layer. Available sizes in 2-layer: 25×35, 30×45, 35×35, 35×55, 67×52 and 70×70 cm.
Coolant: quantity and placement
- For a chilled shipment of up to 24 hours in a well-insulated box, 2 to 3 gel packs are often sufficient. Scale up at high outdoor temperatures or for longer transit.
- Place the coolant on top of the meat: cold air sinks and so cools the entire contents evenly.
- Freeze coolant through for at least 24 hours at −18 °C before packing. Half-frozen gel packs are the most common mistake.
- Fill empty space with product or extra coolant.
- Ship at the start of the week.
Browse the ice packs, the rigid cooling elements for returnable systems, or the full range of coolants.
Large volumes
Butchers, meat processors and online butchers typically get through large quantities on a structural basis. Ordering by the pallet is then considerably cheaper than by the case, and annual contracts at fixed rates are available for regular buyers. Custom sizes are produced to order with a lead time of 2 to 4 weeks. Also see the selection for the food sector or request a quote.
Frequently asked questions
Which box do I use for fresh meat with next-day delivery?
An EPS box with thick walls and 2 to 3 gel packs. The thick wall absorbs delays; for meat you deliberately do not choose the lightest box that only just makes it.
How many gel packs do I need?
For a chilled shipment of up to 24 hours in a well-insulated box, 2 to 3 gel packs are often sufficient. At high outdoor temperatures, with a lighter box or a longer transit time, scale that number up.
How do I ship frozen meat?
With more cooling mass and thick-walled packaging, even on shorter runs. For 24 to 48 hours, combine a thick-walled version with plenty of ice packs.
Can I use my own cardboard box?
Yes. An insulated box liner turns your existing shipping box into chilled packaging, without extra volume or warehouse space. For one-day deliveries the 2-layer version with self-adhesive strip is sufficient.
Do I need drainage holes?
For own distribution with thawing product, yes, so moisture can escape. If you ship via a parcel carrier, choose a closed version.