The frozen food market in North America is the largest in the world. Estimates value the industry at $91 billion annually which means it makes up nearly half of the global market. With the rise of convenient, yet elevated, in-home dining experiences and meal kits that require little to no cooking, it shows no signs of losing its substantial market valuation anytime soon. As demand continues to increase and new brand options emerge and expand, getting these products efficiently and safely to the end consumer is more essential than ever.
Frozen food packaging plays a vital role in ensuring perishable items maintain their quality and safety throughout the supply chain journey. The “cold chain,” the term referring to the entire temperature-controlled supply chain, is critical for frozen foods, where even minor changes in temperature can lead to spoilage or a decline in quality. Packaging methods such as vacuum sealing, insulated containers, and gel packs are commonly used to extend shelf life, prevent freezer burn, and expand delivery range capabilities. However, retailers and distributors often face challenges when it comes to shipping and receiving frozen food products in their optimal condition.
The Dilemma
A major pain point of frozen food retailers arises from improper packaging which directly affects the product’s temperature-controlled climate. Frozen waffles, for example, are bagged and placed into their branded boxes in a cold room where hot melt adhesive seal is applied at 350 degrees Fahrenheit, before going into a blast freezer where temperatures change from 40 degrees F to negative 40 degrees F almost instantly. This intense, sudden fluctuation can crack and damage packaging adhesive insufficient for the task, breaking an important barrier between the sealant and outside temperatures.
Another issue retailers encounter is maintaining sealant integrity in the cold chain during transportation. Delays caused by traffic or logistical errors, as well as tears in the lining or inadequate material can expose frozen foods to higher temperatures for extended periods and put the product’s quality in jeopardy. Additionally, not all shipping methods or vehicles are equipped with sufficient refrigeration capabilities, creating even more obstacles in delivering frozen food.
Added challenges lay in inventory management and predicting demand accurately. The perishable nature of frozen food means excess inventory can lead to waste if products cannot be sold in time. Retailers are constantly balancing the cost of holding inventory against the risk of stock-outs, especially for seasonal or popular items. Then there is the need for specialized storage space (freezer warehouses or cold storage facilities) adding to operational complexities and costs. As consumer preferences shift toward online grocery shopping and home delivery services, adapting logistics to meet these demands while maintaining the appropriate temperatures will be crucial.
The Opportunity
All these components – temperature, delivery speed, warehousing, packaging reliability, inventory management, cold chain integrity – need to be in seamless alignment for frozen food products to make it to the consumer in their intended state. Frozen food packaging and transport is some of the most complicated and detailed packaging and shipping processes that can easily become overwhelming and costly when done without a working knowledge of the industry or proper guidance and support. The Food and Drug Administration (FDA) regulations and manufacturer safety and health requirements in place to protect consumers can be a major deterrent for many retailers hoping to traverse the frozen food market.
Retailers need robust packaging and transportation systems in place to monitor temperatures continuously and certify shipments are delivered on time to avoid product deterioration and even consumer loss to other brands.
Guidance from industry insiders with experience in frozen food packaging is key for retailers to build and maintain their product’s market share. Collaboration with transportation companies and technology providers can also help retailers navigate some of these challenges. Premier has been involved in meal kit packaging since it’s first big boom over a decade ago. By tackling these distinct obstacles involving frozen food packaging and logistics together, we can enhance your operational efficiency and boost customer satisfaction by ensuring the safe delivery of high-quality products.