How to Ship Frozen Food Safely (2026 Guide)
Written by Valentin Scemama, Logistics & Insurance Expert at Secursus.
⚡ Quick Answer: The Formula for Frozen Shipping To keep food frozen for 48 hours, use a Styrofoam cooler with minimum 1.5-inch thick walls inside a corrugated box.
- Coolant: Use Dry Ice (5-10 lbs for 24h). Gel packs are only for chilled goods, not frozen.
- Packing: Place dry ice on top of the food (cold air sinks).
- Timing: Only ship via Next Day Air or 2-Day service on Mondays or Tuesdays.
Shipping frozen food is unforgiving. One delayed truck or a thin cooler wall, and your shipment becomes an expensive loss. Whether you are shipping high-stakes wagyu beef or delicate ice cream, the challenge is identical: maintaining a sub-zero chain of custody without reliable refrigeration during transit.
In 2026, successful cold chain shipping relies on a precise calculation of Insulation + Coolant Mass + Transit Speed. This guide breaks down the exact protocols used by professional food distributors.
Before you pack a box: run these 3 checks every time
Before anyone starts packing a shipping container, lock in three variables: product, temperature, time.
1. Understand how your product behaves under heat
- Dense cuts of frozen meat (e.g., a 2 kg beef roast) hold cold longer thanks to their mass.
- Ice cream and dairy lose quality fast: a single thaw/refreeze cycle destroys texture.
Strategy: Do not pack all SKUs the same way. High-value frozen meat and seafood require more dry ice and tighter shipping windows than processed meals.
2. Set a hard temperature target
"Keep it frozen" is not a spec. For most items, keep core product temperature at or below 0°F (-18°C). Treat prolonged exposure in the "danger zone" (40–140°F / 4–60°C) as unsafe, following FDA and USDA guidance.
3. Plan for actual transit time
Carrier labels are marketing. A "2-Day" route often takes 50 hours inside trucks and hubs. Rule of thumb: Build in a buffer of 25–50% on top of the scheduled transit time. If you cannot cover the real transit time with your coolant, don’t ship that product.
💡 Pro Tip: Always ship early in the week (Monday to Wednesday). Never let a frozen package sit in a carrier warehouse over the weekend.
Cost to Ship Frozen Food: Standard vs Overnight Prices
You might be in the process of shipping frozen food, and you ask yourself how much it costs. Find below a quick table that shows prices of standard and overnight delivery.
| Package Size & Weight | Overnight Service | Shipping Fee (Est.) | Packaging Cost (Cooler + Dry Ice) | Total Estimated Cost |
|---|---|---|---|---|
| Small (5-7 lbs) (e.g. Ice Cream, Chocolates) | FedEx Priority UPS Next Day Air | $80 - $110 | $15 - $25 | $95 - $135 |
| Medium (10-15 lbs) (e.g. Steaks, Seafood) | FedEx Priority UPS Next Day Air | $125 - $160 | $25 - $35 | $150 - $195 |
| Large (20-30 lbs) (e.g. Bulk Meat, Meals) | FedEx Priority UPS Next Day Air | $200 - $300+ | $40 - $60 | $240 - $360+ |
Dry ice vs Gel packs: pick the right cold engine
- Dry ice (CO₂ solid): Best for fully frozen meat and seafood on routes up to 48–72h. It keeps items rock-hard but requires vented containers (hazardous material).
- Gel packs: Best for chilled items (0–4°C). They do not provide a deep-freeze.
Dry Ice Quantity Guide (Estimate)
| Package Weight | 24h Transit | 48h Transit |
|---|---|---|
| Small (5-10 lb) | 3-5 lb | 5-8 lb |
| Medium (10-15 lb) | 5-7 lb | 8-12 lb |
| Large (20+ lb) | 8-10 lb | 15-20 lb |
🥩 Special Guide: How to Ship Frozen Meat (Steaks, Game, Poultry)
Shipping raw meat is riskier than shipping pre-cooked meals. If a steak thaws and refreezes, bacteria multiply, and the texture is ruined.
- Vacuum Seal Everything: Oxygen is the enemy. Before freezing, vacuum seal your cuts to prevent "freezer burn" during transit.
- The "Meat Brick" Technique: Freeze your individual cuts, then stack them together tightly to form a single, dense block. A 10 lb block of meat stays frozen much longer than 10 separate 1 lb packages.
- Coolant Placement: For meat, place dry ice on top and around the block. Never let dry ice touch the meat directly (it causes freezer burn)—always have a layer of cardboard or bubble wrap in between.
What carriers cover (and what they don’t)
Shipping companies like FedEx, UPS, and USPS will move your frozen items, but they will not manage your cold chain. Standard liability is often capped and strictly excludes loss from temperature fluctuations.
The Secursus Strategy for Food Businesses
While Secursus (like all insurers) excludes spoilage of perishable foods due to temperature failure, we are essential for the rest of your logistics:
Protect your Equipment & Dry Goods: Food businesses don't just ship steak. You ship expensive vacuum sealers, data loggers, branded packaging, and non-perishable merchandise. Relying on carrier liability for these high-value assets is a risk you don't need to take.
- Rates: 0.6% to 1% of value.
- Coverage: Full value against Loss, Theft, and Damage.
📦 Insure your equipment and dry goods now
Frequently Asked Questions (FAQ)
What is the cheapest way to ship frozen food?
The cheapest way is often USPS Priority Mail Express or regional ground services if the destination is close (1 day). However, saving money on slower services usually results in spoiled food. Never use standard ground shipping for frozen items.
How to send frozen food in the mail safely?
You must use an insulated Styrofoam cooler inside a cardboard box. Use 5-10 lbs of dry ice for a 24-hour trip. Ensure the package is marked "Perishable" and "Dry Ice" (Class 9 label) if applicable.
Can you reuse dry ice for shipping?
No. Dry ice sublimates (turns into gas) and disappears. You must buy fresh dry ice immediately before packing your shipment to ensure maximum cooling time.
