Can you ship frozen food without it melting?

Yes — frozen food can be shipped without thawing using passive insulated packaging with phase change material (PCM) gel bricks at −18°C or −21°C, or dry ice. A properly packed insulated box with the right refrigerant quantity can maintain frozen temperatures for 18–30 hours in Australian summer conditions — enough for most overnight domestic deliveries.

What refrigerant should I use to ship frozen food in Australia?

For most frozen food shipments, PCM gel bricks formulated at −18°C or −21°C are the most practical choice — they maintain the correct frozen temperature, have no dangerous goods classification for air freight, and are fully reusable. Do not use standard gel packs (designed for 2–8°C chilled applications) for frozen food. Dry ice works for longer transit times but requires more careful handling.

How much refrigerant do I need to ship frozen food?

As a general rule, aim for at least 30–40% of your pack weight in refrigerant for frozen applications in Australian summer conditions (30°C+ ambient). Always pre-chill both the insulated box and the product before packing, and eliminate air gaps in the packaging to maximise performance.

What temperature does frozen meat and seafood need to stay at during shipping?

Frozen meat, seafood, and poultry should be kept below −18°C during shipping. Australian food safety standards allow short transit excursions to around −12°C, but you should aim to maintain −18°C throughout. Ice cream and frozen desserts are more demanding — partial thawing causes irreversible texture damage even if the product refreezes.

Can I Ship Frozen Food Without It Melting? A Practical Australian Guide

Yes, you can absolutely ship frozen food without it thawing — but only if you do it properly. A solution that works fine in winter can fall apart completely when Australian summer ambient temperatures hit 35–40°C. Here’s how to get it right from the start.

What Temperature Does Frozen Food Need to Stay at During Shipping?

Product type	Required temp	Notes
Ice cream and frozen desserts	Below −18°C	Most demanding — partial thaw causes irreversible texture damage even if refrozen
Frozen meat, seafood, poultry	Below −18°C	Short transit excursions to −12°C generally acceptable under Australian food safety standards
Frozen ready meals	Below −18°C	Many manufacturers accept delivery at up to −15°C
Frozen pharmaceuticals/biologics	Product-specific	Often tighter requirements than food — always check product specification

What Are the Two Main Approaches to Shipping Frozen Food?

Option 1: Passive Insulated Packaging with PCM or Dry Ice

An insulated box packed with pre-frozen refrigerant maintains temperature for the duration of transit without any power source. Your three main refrigerant options:

Dry ice (solid CO₂): Sublimates at −78.5°C — the coldest readily available refrigerant. Works well for longer transit times but requires handling precautions, has strict air freight limitations, and disappears during transit
PCM gel bricks at −18°C or −21°C: Phase change material that maintains −18°C or −21°C throughout the melt cycle. Safer and easier to handle than dry ice, no dangerous goods classification for air freight, fully reusable. For most overnight frozen food parcels in Australia, well-specified PCM bricks work well and are far more practical
Standard gel packs: Do NOT use for frozen food — standard gel packs are designed for chilled (2–8°C) applications, not frozen

Option 2: Refrigerated Courier or Freezer Vehicles

For high volumes, long distances, or tight temperature requirements, refrigerated transport is more reliable than passive packaging. Higher cost but more predictable performance, and reduces product loss significantly for consistent frozen freight volumes.

How Long Can Insulated Packaging Hold Frozen Temperature?

A properly packed insulated EPS box with an appropriate quantity of −18°C PCM bricks in Australian summer conditions (30°C+ ambient) should maintain frozen temperatures for 18–30 hours — enough for most overnight domestic deliveries. For longer transits — interstate road freight over 24 hours or deliveries to remote areas — you need a larger refrigerant mass or refrigerated transport.

What Are the Most Common Reasons Frozen Food Thaws in Transit?

Not pre-conditioning packaging: Packing warm product or a warm box means refrigerant must work overtime just to get everything cold — and runs out faster
Too little refrigerant: Aim for at least 30–40% of pack weight in refrigerant for frozen applications in Australian summer conditions
Air gaps in packaging: Air gaps allow warm air to convect around refrigerant, dramatically reducing effectiveness — pack tightly, fill gaps
Wrong gel packs: Standard gel packs freeze at 0°C — not cold enough for frozen product
Underestimating transit time: Design for worst-case transit time, not best-case — overnight can run to 30+ hours in peak periods

Envirofreeze supplies PCM gel bricks at −15°C, −18°C, and −21°C, insulated mailers, and thermal pallet covers. Contact our team → to discuss the right specification for your transit routes and product types.