Cold chain express delivery cost is a critical part of moving vaccines, fresh food and biologics. In 2025, refrigerated freight spot rates hover around US$2.35 per mile, while contract rates are higher. The global cold chain market is booming, with a value of US$316 billion in 2024 and projections of US$1.61 trillion by 2033. Understanding what drives your cost helps you keep products safe without overspending. This guide gives you practical strategies, real data and expert insight to help you control costs and stay competitive.
This article will answer:
What factors influence cold chain express delivery cost? – including temperature needs, shipment size, distance and mode.
How do reefer freight rates compare with dry van and flatbed rates? – using up to date 2025 rate data.
Which packaging options affect cost and how can you save money? – comparing EPP boxes, dry ice packs, gel packs and VIP liners.
How do different transport modes (air, sea, road) impact cost? – showing why air can be 4–6 times more expensive than sea freight.
What trends are shaping cold chain costs in 2025? – exploring technology, sustainability and market growth.
What factors drive cold chain express delivery cost?
Direct answer
The cost of cold chain express delivery is determined by temperature requirements, shipment size, transport distance, mode of transport, specialised handling, seasonality and value added services. Products that need ultra low temperatures or strict humidity control require specialised equipment and skilled handling, driving the price up. Smaller shipments cost more per unit because you cannot spread fixed costs over many items, while long routes and remote destinations increase fuel and labour costs. Air freight offers speed but is the most expensive option, whereas ground or sea freight can reduce cost but may extend transit times.
Expanded explanation
From a shipper’s perspective, temperature control is the biggest cost driver. Ultra cold goods such as vaccines need dry ice or cryogenic freezers and incur higher capital and energy costs. Standard refrigerated goods (2–8 °C) travel in reefer trucks or insulated containers; the equipment costs and extra fuel consumption raise rates by comparison with ambient freight. Shipment size and volume also matter. Less than truckload (LTL) cold shipments may cost more per pound because they cannot benefit from freight consolidation. In contrast, full truckloads spread fixed costs across more units. Distance and route determine fuel and driver wages; shipping to rural or remote areas means fewer backhauls and higher “deadhead” miles. Special handling for fragile goods or hazardous materials adds labour and equipment, while seasonal demand (e.g., holiday turkeys or produce harvests) causes price spikes. Finally, value added services such as insurance, real time tracking and expedited delivery elevate the total cost.
How do reefer rates compare with dry van and flatbed rates?
Shipping temperature controlled freight costs more than moving dry cargo. In June 2025, refrigerated truck spot rates averaged US$2.35 per mile, with contract rates around US$2.71 per mile. By December 2025, national spot trucking rates for reefer freight reached US$2.64 per mile, compared with US$2.27 per mile for dry van and US$2.54 per mile for flatbed. Data from financing provider Scale Funding show that reefer rates averaged US$2.62 per mile nationwide, with the Midwest reaching US$2.97 per mile and the Southeast falling to US$2.22 per mile.
| Cost metric | Temperature controlled freight (reefer) | Dry van or flatbed freight | What it means for you |
| Spot rate (June 2025) | US$2.35 per mile average | Dry van ~US$2.03 per mile | Reefer loads command a premium because of specialised equipment. |
| Contract rate (June 2025) | US$2.71 per mile | N/A | Long term contracts stabilise costs but remain higher than spot rates. |
| Spot rate (Dec 2025) | US$2.64 per mile | Van: US$2.27 per mile; Flatbed: US$2.54 per mile | Current reefer pricing is 15–30 ¢/mile higher than dry van and may include additional fuel surcharges. |
| Regional variation (Dec 2025) | Midwest US$2.97 per mile; Southeast US$2.22 per mile | N/A | Prices fluctuate with regional demand and capacity; planning around harvest seasons can lower costs. |
Practical tips and suggestions
For short regional routes: Consolidate multiple shipments into a full truckload to spread fixed costs. Negotiate contract rates during off peak seasons to lock in lower per mile fees.
For cross country or multi state shipments: Compare reefer spot and contract rates across regions. Choose carriers with balanced networks and high load to truck ratios to avoid empty backhauls and reduce per mile costs.
For high value commodities (e.g., biologics): Pay for premium monitoring and route optimisation. The added cost protects product integrity and can prevent expensive spoilage claims.
Real world case: A produce carrier in Yuma to Los Angeles lane averaged US$3.73 per mile in 2025—about US$0.50 per mile higher than the previous year. The premium reflected high demand and limited reefer capacity, highlighting the importance of timing and long term contracts in cost control.
How can you reduce cold chain express delivery cost without sacrificing quality?
Direct answer
Controlling cold chain costs relies on optimising packaging, planning routes, managing inventory and partnering with specialised logistics providers. Reusable insulated containers (like EPP boxes), right sized coolant and smarter route planning reduce waste. Choosing the appropriate mode of transport and negotiating long term contracts stabilises expenses. Implementing real time monitoring and predictive maintenance prevents temperature excursions, cutting spoilage and regulatory penalties.
Expanded explanation
Packaging is often an overlooked cost driver. Portable Expanded Polypropylene (EPP) boxes offer a durable, reusable option. Small EPP boxes cost about US$20–50 each, while commercial reusable models can exceed US$100, but the cost per trip drops to US$0.50 if the box completes 300 cycles. Selecting the right density and wall thickness affects durability and insulation: thicker walls and interlocking lids improve thermal performance but raise unit price. Dry ice and gel packs are another major expense. In 2025, dry ice packs retail for US$1.38–2.10 per pound, while gel packs cost US$0.85–1.25 and Phase Change Material (PCM) packs cost US$2.50–3.20. EPS foam kits cost US$4–7, whereas high performance VIP liners cost US$13+ but cut dry ice use by 40 %, delivering savings over repeated shipments. Carriers also charge hazmat fees (around US$8 per parcel for dry ice shipments). Balancing coolant type, packaging quality and reuse cycles delivers the best return on investment.
Which packaging options affect cost?
The choice of container and refrigerant directly affects both cost and performance.
| Packaging option | Typical unit cost | Typical application | What it means for you |
| Small EPP box (2025) | US$20–50 each | Meal kits, grocery delivery | Durable and reusable; cost per trip falls with higher reuse cycles. |
| Commercial EPP box | US$100+ per box | Pharma shipments, multi day routes | Higher up front cost but low cost per trip when reused (e.g., US$0.50/ trip over 300 cycles). |
| Dry ice pack | US$1.38–2.10 per lb | Deep frozen products (–78 °C to –20 °C) | Offers high cooling intensity; hazmat fee (~US$8/parcel) applies; good for seafood and biologics. |
| Gel pack | US$0.85–1.25 per lb | 0–8 °C products (meal kits, produce) | Lower cost than dry ice; easier handling; shorter hold times (~36 h). |
| PCM pack | US$2.50–3.20 per lb | Custom temperature ranges (–25 °C to +18 °C) | Reusable and precise; higher cost but longer hold times (~60 h). |
| EPS kit | US$4–7 per kit | Single use shipments | Economical but limited insulation; generates more waste. |
| VIP liner | US$13+ per liner | High value shipments, long routes | Reduces dry ice requirement by ~40 %; payback within a few shipments. |
| Hazmat fee | US$8 per parcel | Dry ice shipments | FedEx and UPS charge this; plan for it in cost models. |
Practical tips and suggestions
Right size your packaging: Oversized boxes waste coolant and increase shipping costs. Match box volume to payload and route length, then choose the appropriate coolant. For same day routes, thinner walls and handles speed handling; for overnight lanes, invest in thicker insulation.
Calculate true cost per trip: Include box purchase price, expected replacement cost, cleaning/handling labour and loss rates to understand the real cost. A US$150 EPP box over 300 cycles costs only US$0.50 per trip.
Use VIP liners judiciously: At roughly US$13+ per liner, VIP panels can reduce dry ice needs by 40 %, saving money on coolant and reducing package weight.
Minimise hazmat surcharges: When shipping with dry ice, bundle shipments to reduce per parcel hazmat fees or use ground transport below 200 lb to avoid them.
Prioritise reusability: Develop return and cleaning systems so reusable EPP boxes come back in good condition, lowering per delivery costs.
Actual case: A meal kit operator invested in higher density EPP boxes with better lid seals; although each box cost more, the company lowered reshipments and cut delivery failures. Lifecycle cost analysis showed that investing in durable packaging improved customer satisfaction and reduced overall logistics cost.
How do shipping modes affect cold chain delivery cost?
Direct answer
Transport mode is one of the largest levers you can pull to control cold chain express delivery cost. Air freight is the fastest but can cost 4–6 times more than sea freight for the same load. Road transport offers a balance between speed and cost; reefer trucks charge higher per mile rates than dry vans. Sea freight has the lowest cost per unit but requires longer lead times and investment in advanced reefer containers.
Expanded explanation
Choosing between air, ocean and ground depends on cargo value, shelf life and delivery window. Air freight is charged by weight or volume. In 2025, domestic air shipments of 200 lb can cost US$500–600. International air freight rates range US$3–6 per kilogram, roughly 4–6 times the cost of ocean freight. Air carriers also impose hazardous materials restrictions and surcharge for dry ice. Ocean freight is ideal for bulk and non urgent shipments. Container rates from Shanghai to Los Angeles averaged US$2,522 per 40 ft container in mid 2025, equivalent to a few cents per pound. The trade off is transit time and port congestion. Road transport remains essential for domestic distribution; in 2025, full truckload (FTL) dry van rates averaged US$2.20–2.50 per mile, while reefer trucks averaged US$2.62–2.64 per mile.
Air vs sea vs ground: which is cost efficient?
| Mode | Typical cost | Speed | Best for | Considerations |
| Air freight | US$3–6 per kg or US$500–600 for 200 lb domestic shipment | Fastest (1–3 days) | Urgent or high value goods (pharma, biologics) | 4–6× the cost of ocean; hazmat limits; emissions footprint. |
| Ocean freight (FCL) | US$2,522 per 40 ft container (Shanghai→LA) | Slow (10–30 days) | Bulk food, beverages, stable vaccines | Low cost per unit; requires advanced reefer containers and careful planning. |
| Road freight – reefer FTL | US$2.62–2.64 per mile (average) | Moderate speed (2–5 days cross country) | Domestic produce, meat, meal kits | High per mile cost due to equipment; sensitive to fuel prices and seasonal demand. |
| Road freight – dry van FTL | US$2.27 per mile (average) | Moderate speed | Ambient goods, packaging materials | Lower cost but no temperature control. |
| LTL refrigerated shipments | US$300–1,500 per shipment or US$0.20–0.45 per pound | Variable | Small batches, partial pallets | Higher cost per unit; multiple stops can increase temperature variation. |
Practical tips and suggestions
For urgent deliveries: Use air freight only when product value or regulatory requirements justify the cost. Combine with temperature controlled packaging to maintain product integrity and avoid spoilage penalties.
For international bulk shipments: Opt for ocean freight in modern reefer containers. Plan for longer transit times and build inventory buffers. Use multi modal strategies—sea to port plus road for domestic distribution—to balance cost and speed.
For domestic distribution: Choose a combination of FTL or LTL reefer trucking depending on volume. Consolidate loads, align shipments with carriers’ preferred lanes and negotiate fuel surcharge caps.
For remote regions: Consider cooperative purchasing of equipment or partnering with local carriers to reduce deadheading and equipment repositioning costs.
Actual case: In July 2025, UNICEF shipped over 500,000 doses of pneumococcal vaccine by sea from Belgium to Côte d’Ivoire. The sea route reduced greenhouse gas emissions by up to 90 % and cut freight costs by 50 % compared with air transport. Planning ahead and leveraging ocean logistics can significantly reduce cold chain delivery expenses for large shipments.
What are the latest 2025 trends influencing cold chain delivery cost?
Trend overview
The cold chain industry is evolving rapidly, and these changes have a direct impact on cost. Technology adoption is accelerating: networks of IoT sensors collect real time temperature data, while AI powered route optimisation minimises delays and reduces fuel consumption. Solar powered cold storage and renewable energy integration lower operating costs and extend cold chain reach in areas with unstable electricity. Blockchain platforms provide tamper proof shipment records, enabling faster dispute resolution and regulatory compliance. Sustainable packaging reduces waste and long term costs, with reusable containers and eco friendly materials gaining popularity. Market demand is shifting as Millennials drive fresh produce consumption; this demographic accounts for 68 % of new produce dollars, supporting growth in reefer transportation.
Latest progress at a glance
Stable reefer rates: Despite market volatility, national reefer spot rates have stabilised around US$2.35–2.64 per mile. Contract premiums of US$0.35–0.40 per mile provide carriers with greater cost certainty.
Dry ice pricing improvements: Captured emission CO₂ now supplies 41 % of dry ice production, helping to keep retail prices between US$1.38 and $2.10 per pound. Bulk contracts and VIP liners can reduce dry ice usage by 40 %, cutting costs.
Reusable packaging gains: High density EPP boxes and better lid designs extend life cycles, lowering cost per trip to around US$0.50. Companies are investing in return logistics and cleaning systems.
AI & analytics adoption: Predictive maintenance and route optimisation reduce fuel costs and prevent temperature excursions. Real time monitoring systems save carriers 5–10 hours per week in productivity and reduce spoilage.
Sustainability drives market growth: Demand for eco friendly packaging and lower carbon transport is rising. Solar powered cold storage and carbon capture dry ice production help meet environmental goals while lowering energy costs.
Market insights
Consumer preferences are changing. Millennials, who now account for 68 % of new produce spending, favour fresh, convenient and sustainably sourced products. This shift fuels the need for reliable cold chain logistics, especially for e commerce grocery deliveries. The global cold chain market, valued at US$316.34 billion in 2024, is projected to reach US$1.61 trillion by 2033, growing at a 20.1 % CAGR. In the U.S., the cold chain market is expected to more than double from US$34.67 billion in 2024 to US$75.96 billion by 2032. This rapid expansion reflects investments in infrastructure, technology and sustainable solutions. However, rising operational costs and equipment shortages could squeeze margins if shippers fail to optimise their strategies.
Frequently asked questions
Q1: How much does cold chain express delivery cost per mile?
For temperature controlled trucking, spot rates averaged US$2.35 per mile in mid 2025 and US$2.64 per mile in December 2025. Contract rates can add about US$0.35–0.40 per mile. Rates vary by region, with Midwest lanes reaching US$2.97 per mile and Southeast as low as US$2.22 per mile.
Q2: How do packaging choices influence cold chain costs?
Packaging determines insulation performance, coolant requirements and reusability. Small EPP boxes cost US$20–50 and reusable models over US$100, but cost per trip can drop to US$0.50 with multiple cycles. Dry ice packs range US$1.38–2.10 per pound, gel packs US$0.85–1.25, and PCM packs US$2.50–3.20. Higher priced VIP liners reduce dry ice usage by 40 %.
Q3: Is sea freight cheaper than air for cold chain shipments?
Yes. Air freight is typically 4–6 times more expensive than ocean freight. Shipping 500 lb by air from Los Angeles to New York may cost over US$2,000, while the same load by truck might cost US$500–700. Sea freight container rates from Shanghai to Los Angeles averaged US$2,522 per 40 ft container in 2025. However, sea freight requires longer transit times and reliable reefer containers.
Q4: What is the best way to reduce last mile cold chain costs?
Use route optimisation software to minimise travel distance, schedule deliveries during off peak traffic and coordinate drop off windows with customers. Employ reusable packaging and right sized coolant to prevent waste, and partner with local micro fulfilment centres to shorten delivery routes. Encouraging customer participation in returns programmes helps recoup packaging costs.
Q5: Why do refrigerated loads cost more per mile than ambient loads?
Refrigerated carriers face higher capital costs for trailers and refrigeration units, limited capacity, few alternative modes (intermodal or rail), seasonal demand spikes and geographic imbalances that require expensive repositioning. These factors contribute to higher per mile rates compared with dry vans.
Summary and recommendations
Cold chain express delivery cost is influenced by multiple variables: temperature requirements, shipment size, route length, transport mode and packaging. Refrigerated freight rates averaged US$2.35–2.64 per mile in 2025, reflecting specialised equipment and fuel consumption. Packaging choices—from EPP boxes and dry ice packs to VIP liners—affect unit cost and failure risk. Air freight provides speed but costs 4–6 times more than ocean, while ground and sea transport offer economical alternatives. Advanced technologies such as IoT sensors, AI route optimisation and blockchain improve visibility and reduce waste, helping to contain costs. Sustainable practices (reusable containers, solar powered storage, carbon capture dry ice) balance environmental goals with economic benefits.
Actionable next steps
Assess your product’s temperature and transit needs. Identify whether your goods require ambient, chilled, frozen or ultra cold conditions and select suitable packaging and equipment.
Optimise packaging. Choose reusable containers such as high density EPP boxes and VIP liners; calculate true cost per trip and right size coolant to avoid waste.
Plan your routes. Use predictive analytics and route optimisation to reduce miles, fuel consumption and delivery time. Schedule shipments during off peak hours and consolidate loads whenever possible.
Select the right transport mode. For urgent and high value items, consider air freight but evaluate cost trade offs. For bulk or non urgent shipments, choose sea or road and leverage multi modal solutions.
Partner with experts. Work with cold chain 3PL providers who offer transparent pricing, advanced monitoring and sustainability expertise. Negotiate long term contracts to lock in rates and ensure capacity.
Invest in technology and sustainability. Deploy IoT sensors, AI and blockchain to enhance visibility and compliance. Adopt renewable energy sources and eco friendly materials to reduce operational costs and carbon footprint.
By implementing these strategies, you can maintain product integrity, satisfy regulatory requirements and keep cold chain express delivery costs under control.
About Tempk
Tempk is a leading provider of innovative cold chain packaging and logistics solutions. We specialise in reusable insulated containers, gel packs, dry ice packs and temperature controlled bags that keep your products safe from origin to destination. Our R&D team focuses on sustainability and efficiency: captured emission CO₂ for dry ice production, reusable EPP boxes with durable lid seals, and solar compatible storage options. We support clients across food, pharmaceutical and biotech sectors with customised solutions and transparent pricing.
Call to action
Ready to optimise your cold chain operations? Contact Tempk’s experts for a personalised consultation. We’ll help you select the right packaging, plan efficient routes and implement technology that reduces cost while protecting product quality.
