How to Ship Perishable CPG Products in 4 Steps

Shipping perishable goods is tricky but crucial. Here’s how to ensure products like frozen foods, dairy, and fresh produce arrive in perfect condition:

1. Choose the Right Packaging: Use proper insulation (e.g., polyurethane foam, paper-based materials) and water-resistant, sealed boxes.
2. Control Temperature: Use dry ice for frozen items or gel packs for refrigerated goods. Track temperatures in real time with tools like Tive trackers.
3. Plan Efficient Shipping: Opt for fast delivery methods (e.g., UPS Next Day Air), minimize transit time, and monitor shipments.
4. Follow Regulations: Comply with FDA’s FSMA and HACCP standards, use proper labeling, and maintain quality control.

Quick Comparison of Cooling Methods

How to Pack and Ship Perishable Refrigerated Food

Step 1: Select Proper Packaging

Choosing the right packaging is key to ensuring products arrive safely and in good condition. Proper insulation and protection play a big role in maintaining product quality during delivery.

Insulation Materials and Methods

The insulation material you choose impacts both temperature control and cost. Here are some common options:

Polyurethane foam provides top-tier protection for items that require strict temperature control during extended transit. For shorter trips, paper-based insulation offers a solid balance between performance and eco-friendliness, making it a favorite among shippers looking for greener options.

Strong, Water-Resistant Packaging

Water damage can ruin perishable goods, so it’s important to take precautions. Here’s how you can protect your packages:

• Use double-walled corrugated boxes for added durability
• Opt for water-resistant coatings or eco-friendly varnishes

Interestingly, nearly half of shoppers (49%) are willing to pay extra for sustainable packaging . This demand has led to the development of plant-based varnishes that offer water resistance comparable to traditional options.

Package Sealing and Labels

Proper sealing and labeling are essential for compliance and safety. Packaging needs to include durable, easy-to-read markings in English . Key steps include:

1. Ensuring all seams are airtight
2. Adding temperature indicators on the package exterior
3. Clearly displaying handling instructions on the main panel

"Shipping perishable goods requires a strategic approach and the right tools to ensure items reach their destination fresh and intact" .

For hazardous materials, labels must be placed on the package surface (not the bottom), near the proper shipping name, and remain visible throughout transit. In the first nine months of 2020 alone, there were 10,000 reported HAZMAT incidents , underscoring the importance of correct packaging practices.

Step 2: Control Temperature

Keeping a consistent temperature is key to maintaining product quality and avoiding spoilage.

Dry Ice vs. Gel Packs

Deciding between dry ice and gel packs depends on your shipping needs. Here’s a quick comparison:

"It requires considerably more energy to convert dry ice from solid to gas than it does for gel packs from solid to liquid, which is why dry ice helps maintain lower temps for higher durations." – Al Muzahimi, TSS Thermalist

Once you’ve chosen your cooling method, focus on arranging the elements for the best results.

Cooling Element Layout

Proper placement of cooling elements ensures even temperature control. Here’s how to do it:

• Dry Ice Placement: Place dry ice on top of the products, as cold air sinks naturally. Fill any empty spaces with loosefill peanuts to maintain stability and temperature.
• Gel Pack Configuration: Surround products with gel packs to create a cold envelope:
  • A bottom layer for base cooling
  • Side packs to protect the edges
  • A top layer to support the natural flow of cool air downward
• Insulation Layers: Add barriers between the cooling elements and the products to prevent freeze damage.

Pairing accurate placement with real-time tracking ensures everything stays at the right temperature.

Temperature Tracking Tools

Modern tracking tools make it easier to monitor temperature during transit. Consider these options:

• Cargo Data‘s Lightning Real Time: Provides live updates on temperature, location, and door status .
• Tive’s 5G Single-Use Tracker: Includes a specialized dry ice probe for frozen shipments .
• Mercury’s TempTale® Ultra Datalogger: Features USB connectivity and automatic PDF reports .

Temperature tracking is especially important since around 10% of pharmaceutical products require strict temperature control .

Lastly, pre-chill insulated containers to reduce the strain on your cooling elements and keep everything running efficiently.

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Step 3: Plan Shipping and Delivery

Maintaining product freshness doesn’t stop at temperature control – it extends to how efficiently you handle shipping and delivery.

Choose the Right Shipping Speed

The shipping speed you select can make or break the freshness of perishable products. For items like perishable CPG goods, delivery time should stay under 30 hours from pickup to destination . Here’s a quick comparison of common shipping services:

While speed is critical, reducing overall transit time is just as important.

Minimize Transit Time

Cutting down transit time takes thoughtful planning and the use of smart technology:

• Route Optimization: Use AI-powered logistics tools to evaluate traffic and weather, ensuring the quickest routes .
• Strategic Scheduling: Ship early in the week to avoid delays over the weekend .
• Temperature Monitoring: Equip shipments with GPS-enabled trackers and cloud-based monitoring systems .
• Multi-Stop Planning: Plan efficient delivery routes for multiple drop-offs .

Companies like Atomix Logistics showcase how streamlined operations can meet 2-day delivery standards through optimized inventory management and cold storage setups .

Stay in Sync with Carriers

Clear communication with carriers plays a key role in solving problems quickly. Here’s how to stay connected:

1. Provide detailed handling instructions and set up automated alerts before shipments go out .
2. Track shipments in real-time during transit .
3. Keep customers informed with real-time updates about their deliveries.

These steps ensure smooth shipping and enhance the overall customer experience.

Step 4: Meet Standards and Rules

Shipping perishable CPG goods requires strict compliance with federal regulations and maintaining quality controls.

FDA and Shipping Regulations

The FDA Food Safety Modernization Act (FSMA) outlines standards for transporting perishable goods. Temperature requirements for common product categories are:

To meet these standards, warehouses should have:

• Systems for temperature monitoring, backed by generators
• Verified hygiene protocols
• Packaging that shows signs of tampering if opened

FDA GDP and HACCP standards also play a key role in ensuring product safety .

Labeling and Documentation Requirements

Proper labeling is critical for legal compliance. The Fair Packaging and Labeling Act mandates clear product identification on the main display panel .

"To avoid misrepresentation and provide information needed to assure proper storage, food labels should include in the name or statement of identity appropriate descriptive terms such as pasteurized, canned, frozen, or dried." – FDA

Required labels must include:

• Product name and identity
• Storage and temperature instructions
• Handling guidelines
• Full shipper and recipient details

For frozen goods, terms like "frozen fresh" or "fresh frozen" can only be used if the items were frozen promptly after being fresh . Proper labeling, combined with quality checks, helps maintain product safety during transit.

Quality Control and Handling Returns

Strong quality control processes are essential to avoid recalls and maintain customer trust. For example, Blue Bell Creameries had to recall 30 million liters of ice cream in 2015 due to listeria contamination . Here’s how to strengthen your quality control:

• Inspection Protocols: Set clear criteria for outgoing shipments and returned products, including temperature logs and visual checks.
• Returns Management: Use a tracking system to document reasons for returns, receipt dates, product conditions, and related paperwork.
• Data Analysis: Analyze return trends and quality issues to spot and fix problems early. This helps improve shipping and handling procedures .

Regular audits and staff training on standard operating procedures (SOPs) ensure compliance. Keep detailed inspection and quality check records to show adherence during regulatory audits .

Tips for Better Shipping

Improve your shipping approach with practical advice to handle seasonal shifts, manage costs, and adopt eco-friendly practices.

Weather and Season Changes

During the summer, ensure refrigerant levels are sufficient to keep goods fresh. In winter, focus on better insulation to protect items from freezing temperatures. Consider using tracking devices that are designed to handle extreme seasonal conditions so you can keep an eye on your shipments throughout transit .

Cost vs. Quality Trade-offs

Find the right balance between cost and quality by consolidating shipments, choosing cost-effective methods, and planning deliveries efficiently. For example, partner with fulfillment centers that offer volume-based discounts , use LTL (less-than-truckload) shipping for smaller loads , and aim to schedule deliveries early in the week . These steps help reduce expenses without sacrificing reliability.

Eco-Friendly Packaging Options

Opt for packaging materials like compostable Biocooler Panels, biodegradable Bagasse Packaging, or Modified Atmosphere Packaging (MAP). These materials not only protect your products but also reduce environmental impact . As demand grows for greener solutions, more innovative and sustainable shipping materials are becoming available .

Conclusion

Shipping perishable CPG products requires careful attention to four key areas: packaging, temperature control, shipping planning, and regulatory compliance. With the market for perishable goods shipping projected to hit $5.671 billion by 2025 , these steps are more important than ever.

Proper handling is the foundation of effective shipping. A great example is Island Creek Oysters, which uses insulated packaging and real-time monitoring to maintain temperatures below 45°F. This approach ensures the safety and freshness of sensitive products like seafood .

Efficient delivery systems, such as dynamic route planning and GPS tracking, are crucial for maintaining quality. The global food cold chain last-mile delivery market is expected to grow to $12.4 billion by 2030 , highlighting the increasing demand for optimized logistics.

Regulatory compliance and quality control are also vital. These efforts help reduce the staggering 40% of food waste that occurs before products even reach consumers, while also safeguarding profitability . Businesses that adopt these practices not only meet legal requirements but also position themselves to thrive in a growing market.

As Chris Sherman, CEO of Island Creek Oysters, emphasizes:

"Obviously, [oysters are] a fresh product and a cold temperature is critical because they’re consumed raw and you need to keep them safe… We have monitoring in each package to make sure that when the end user gets it, they can check to make sure that temperature has been maintained."