Food & pet food
THERMOCON offers insulated packaging for temperature-controlled shipping of food and pet food. We help manufacturers, direct-to-consumer producers and online retailers match EPS insulated shippers and coolant packs to product temperatures, order quantities and transit times, from chilled specialty foods to frozen raw pet food portions.
Food and temperatures
The cooling required depends on the product type, processing and manufacturer’s instructions. When selecting insulated packaging, we therefore distinguish between fresh, chilled and frozen products. Requirements can also differ within a product group.
For US shipments, define the temperature from the exact seafood product, processing method, food safety requirements and manufacturer specifications. Smoked products, live animals and frozen fish need separate assessment. For EU-bound fresh fishery products within the relevant regulation, temperatures approaching that of melting ice are required. This EU rule is not a blanket US temperature requirement.[F1]
Use the applicable US product and food safety requirements for meat shipments. For EU-bound minced meat and meat preparations within Regulation (EC) 853/2004, the relevant production, storage and transport limits are +2 °C and +4 °C respectively. These EU values are not universal US limits. Packaging tested only up to +8 °C does not automatically cover a product with a lower maximum temperature.[F1]
Yogurt, cream cheese, aged cheese and chilled desserts may have different temperature requirements. Use the product specifications and applicable food safety controls. For combined shipments, check that individual requirements are compatible and consider container format and order quantity. Covered US motor and rail transportation operations must also meet the FDA sanitary transportation requirements.[F2]
For chocolate, protection from heat and dry conditions are often the main priorities. LAVES, the food safety authority in Lower Saxony, Germany, recommends storage at 12–18 °C. This recommendation is not a statutory transport temperature range. For filled chocolates and specialist recipes, shipping conditions follow the respective manufacturer’s specifications.[F3]
Raw pet food is sold fresh or frozen and has its own product and food safety requirements. For US operations, assess the applicable FDA animal food and sanitary transportation rules. Packaging selection depends on whether the goods must remain frozen and the manufacturer’s temperature specification. The frozen shipping page compares appropriate coolant and packaging options. The cited German monitoring report is background information, not a US shipping rule.[F4][F5]
Frozen products require the specified product temperature throughout transport. Order quantity, potential weekend delays and receipt by the recipient are therefore included in packaging planning. For these shipments, we compare PCM coolants and dry ice, together with suitable insulated boxes.[F6]
The cited EU temperature limits apply to their respective EU legal scope, and the LAVES chocolate recommendation is German storage guidance. For US shipments, use the product specification, applicable food safety rules and manufacturer instructions. FDA sanitary transportation requirements apply to covered US motor and rail operations, with specified exclusions and waivers; they are not a universal temperature table.
Order quantities
Both the smallest order quantity and the largest planned shipment belong in packaging planning. Different combinations of meat packs, pots and glass containers also affect the space required. Packaging tested with an average order does not automatically cover these variations.
This can lead to defined configurations for daily shipping, such as a small and a large box, each with a specified payload and coolant arrangement. The packing team can then identify which configuration is intended for each order.
Insulated boxes and coolants
The US range includes EPS insulated shippers, gel packs, Foam Bricks and rigid PCM packs. Select and prepare coolants to suit the product and box. The achievable product temperature and shipping duration depend on the complete packout and transport conditions.
The quotation specifies whether you receive only the insulated box or also an outer carton, coolants and inserts. Temperature testing, however, considers the fully packed shipment: which foods are placed where, how many coolant packs are used and how long the parcel is in transit. Existing test results are only useful if these conditions match your shipping operation.
Boxes for your own coolant configuration
Lightweight EPS insulated boxes in various dimensions and wall thicknesses are fitted with the required coolants.
Food, coolants and separating layers are considered together when selecting the size.
Shape-stable foam core · Coolant component
Foam Bricks have a foam core that maintains a defined shape when frozen or thawed. Select the coolant version and size for the food, insulated shipper and packing process.
Allow space for the goods, Foam Bricks and any separating layers. Confirm the coolant preparation, arrangement and applicable food-contact documentation for the selected product. A coolant component does not establish the thermal performance of the complete shipment.
Film pouch · Coolant component
Gel packs are available in the US range for chilled and selected frozen shipments. Choose the filling and format with the EPS insulated shipper and payload in mind.
Select the pack dimensions and quantity so that the goods and coolants fit in the intended arrangement. Confirm the preparation instructions and assess the complete packout before changing the coolant type.
Gel packs, ice packs and other formats
Coolants are selected by format, cooling medium and preparation method to suit the food products.
Specify whether the coolant will touch unpackaged food or only bags, trays or other food packaging. This determines the coolant type and food-contact information required.
Selection and testing
Start by recording the product range, permitted temperatures, condition of the goods at packing and order sizes. Destination countries, carriers and the time until receipt complete this information.
The box format, coolants and their arrangement are selected together. This defines which order quantities and product combinations the packaging should cover and which need a different configuration.
For the temperature test, a representative shipment is packed with the intended payload, coolant configuration and starting temperature. The environmental chamber reproduces the agreed ambient temperature profile. Measurements establish whether the goods remain within the specified temperature range for the required transit time.[F7]
The packing instruction describes the permitted goods, their preparation, the required coolants and their positions, and how to close the packaging. It gives the shipping team a clear procedure for each defined packaging configuration.
Questions about insulated packaging
Yes. Pack chilled food at the starting temperature defined for shipping; frozen goods must already be frozen throughout. Do not plan to cool warm products inside the shipping box. Coolants, insulation and payload are matched to keep the prepared goods within the intended temperature range during transport. Food sensitive to cold must also be protected from excessive cooling directly beside the coolant packs.[F8]
Products with compatible temperature requirements, dimensions and order quantities can be grouped into shared shipping configurations. The combinations a packout covers are defined during packaging selection and testing.
THERMOCON also assesses existing packaging. Information about the box, coolants, packout and previous temperature excursions helps with the assessment. The adjustments and tests required can then be established.[F7]
In addition to the box and coolants, coolant preparation, packing time and parcel size all contribute. For a comparison, we need your approximate shipment volume and typical order quantities, including seasonal peaks. Pricing for your chosen configuration is available through the relevant product inquiry.
Specify the configuration, quantity and purpose: a packing trial, thermal test or initial shipping run. Availability, costs and terms are confirmed for each product. A custom prototype requires a separate discussion.
These depend on the product, configuration and quantity required. Provide your initial requirement, expected recurring demand and preferred delivery date. Product-specific ordering terms are confirmed in the quotation.
First, we check whether a standard format can accommodate the goods, coolants and necessary inserts. For a custom size, dimensions, packing processes and expected demand are assessed together. Development costs and any tooling costs form part of this comparison.
THERMOCON USA advice
We help you choose insulated packaging for your product range. Tell us the product type, temperature requirements and smallest and largest orders. Transit times and destination countries help us match the packaging to your needs. Any outstanding details can be discussed together.
Last reviewed: November 1, 2026. The current product specification and the requirements applicable to the shipment remain authoritative.
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