Estimate dry ice mass
Use payload weight, box size, route time, seasonal ambient temperature, and carrier limits before the first lane test.
Tray and seal frozen route
Frozen Ready Meals Cold Chain Packaging Solution
Frozen ready meals often combine trays, film seals, sauces, rice, pasta, vegetables, and sleeves in one pack. The route must keep meals frozen while protecting tray seals, sleeve labels, sauce texture, and stacked tray corners.
Temperature intentPlan for frozen arrival, commonly -18 C or below for frozen ready meal distribution.
Moisture controlUse a moisture barrier and separated dry ice chamber so cartons, sleeves, or bags do not get wet.
Coolant ruleDo not size the packout only by payload weight. Sauce-heavy meals, shallow trays, and paper sleeves need extra attention to seal pressure and condensation.
Receiving checkConfirm product temperature, dry ice remaining, visible thaw, pack condition, and coolant position together.
Choose the packout by route condition
The dry ice amounts below are starting ranges for planning. Final packout should be validated with the exact payload, box size, carrier lane, season, and dry ice limit.
| Route condition | Temperature intent | Tempk packaging setup | Coolant planning range | Coolant position |
|---|---|---|---|---|
| Local meal delivery, 8-18 h | Frozen arrival | EPP or insulated carton, tray stack support, sleeve moisture barrier, separated frozen coolant or dry ice. | 1.0-2.0 kg dry ice for 1-5 kg payload, or validated frozen PCM/frozen gel for short lanes. | Side/top coolant with divider; avoid pressure on film seals. |
| Overnight frozen parcel, 18-36 h | -18 C route intent | Thicker insulation, dry ice pouch, tray corner support, reduced void space. | 2.0-4.5 kg dry ice for 1-5 kg payload. | Top dry ice separated by board; keep logger in product air space. |
| Hot lane or 36-48 h | Validated frozen lane | Higher insulation, stronger tray bracing, route risk check, carrier limit review. | 4.0-7.0 kg dry ice for 1-5 kg payload. | If tray seals lift, reduce pressure and improve bracing before changing dry ice mass. |
For a tighter estimate, start with the Dry Ice Calculator and review insulation choices in the Insulation Material Reference.
Packout sequence that protects frozen quality
Frozen food returns often come from a small layout failure: direct dry ice contact, too much headspace, a wet carton, or a product stack that shifts during handling.
1
Protect tray seals first
Seal failure creates a return even if the temperature curve looks acceptable.
2
Separate dry ice from sleeves and film
Use a divider or dry ice chamber so sleeves do not wrinkle and tray film is not stressed by direct contact.
3
Match packout to meal composition
Sauce-heavy meals, rice bowls, and pasta trays show thaw-refreeze differently; check the real product.
4
Inspect receiving quality
Record temperature, seal integrity, tray cracks, sleeve moisture, sauce separation, and dry ice remaining.
Common losses this packout is meant to prevent
Use these receiving checks when adjusting dry ice mass, insulation thickness, or internal separation.
Quality and packaging risks
- Tray seal lift or corner cracks from pressure and movement.
- Sauce separation after partial thaw-refreeze.
- Wet sleeves or unreadable labels from vapor condensation.
- Warm top trays when coolant is placed only below the stack.
Tools, components, and related routes
Use the product page for the handling logic, then size the first trial with tools and validate the real route.
Choose coolant behavior
Compare dry ice, frozen gel packs, and frozen PCM when choosing the first frozen packout.
Check route risk
Review pickup dwell, last-mile delay, receiving window, and summer routing before launch.
Need a frozen food packout checked before launch?
Share the frozen product type, payload weight, box size, route duration, ambient profile, carrier limits, and receiving checks. Tempk can help choose insulation, dry ice or frozen coolant placement, and validation steps.