When launching a frozen food product, packaging is one of the most critical decisions a brand can make. Beyond just aesthetics, packaging plays a crucial role in preserving freshness, preventing freezer burn, and ensuring product integrity throughout its shelf life. Unlike shelf-stable products, frozen foods face unique challenges such as temperature fluctuations, moisture exposure, and potential physical damage from handling.

To help brands choose the right packaging, we’ll break down key considerations based on different types of frozen food products.

This article is part of our series on packaging considerations across different categories. Read our articles on packaging for self-stable and refrigerated products.

1. Packaging for Frozen Meals & Ready-to-Eat Dishes

Key Considerations

• Must withstand freezing temperatures without cracking or becoming brittle
• May require a strong oxygen and moisture barrier to prevent freezer burn
• Should be microwave- or oven-safe if the product is designed for direct heating

Common Packaging Materials

• Rigid Plastic Trays (PP, PET, CPET) – Used for single-serve frozen meals, these containers provide durability and are often heat-resistant for microwave or oven use.
• Flexible Pouches & Laminates – Multi-layer films with strong barrier properties are used for steamable meal pouches and frozen meal kits.
• Paper-Based Containers – Coated paperboard trays are gaining traction as a more sustainable alternative, often with a plastic or bio-based coating for moisture resistance.

Sustainability & Innovation

• Brands are shifting to recyclable mono-material plastics for improved sustainability.
• Some are adopting compostable trays and coatings, but these must meet freezing and heating performance requirements.

2. Packaging for Frozen Fruits & Vegetables

Key Considerations

• May require moisture-resistant barrier to prevent ice crystal formation
• Consider resealable for convenience and freshness if product is multiuse
• Needs to be flexible for easy storage and handling

Common Packaging Materials

• Flexible Stand-Up Pouches – Made from polyethylene (PE) and/or Polyethylene terephthalate (PET) films, offering durability and strong moisture barriers.
• Vacuum-Sealed Bags – Used to extend shelf life by minimizing oxygen exposure.

Sustainability & Innovation

• More brands are exploring bio-based films with recyclable or compostable properties.
• Lightweighting strategies help reduce plastic usage while maintaining performance.

3. Packaging for Frozen Meats, Seafood & Plant-Based Proteins

Key Considerations

• Must provide an airtight seal to prevent freezer burn and oxidation
• Requires puncture resistance to withstand handling and transportation
• May need portioned or resealable options for consumer convenience

Common Packaging Materials

• Vacuum-Sealed Plastic Films – Offers maximum shelf life by eliminating air exposure.
• Rigid Plastic Tubs & Trays – Used for products like frozen shrimp or plant-based burger patties, providing structural integrity.
• Skin Packaging – A growing trend where a tight film conforms around the product, reducing waste and extending shelf life.

Sustainability & Innovation

• Many brands are transitioning to recyclable vacuum-sealed bags.
• Mono-material films improve recyclability while maintaining food safety.

4. Packaging for Frozen Baked Goods & Dough

Key Considerations

• Requires durable packaging that prevents moisture absorption
• Must maintain shape and texture of delicate pastries, doughs, or bread
• May need freezer-to-oven capabilities for ready-to-bake items

Common Packaging Materials

• Resealable Plastic Bags (LDPE, PP) – Used for frozen bread, muffins, and pastries.
• Paperboard Boxes with Inner Liners – Common for frozen pie crusts and dough sheets.
• Aluminum Trays or Wrappers – Ideal for freezer-to-oven applications like croissants and puff pastry.

Sustainability & Innovation

• Brands are shifting toward paper-based packaging with protective coatings for better recyclability.
• Biodegradable liners are emerging as an alternative to plastic wraps.

5. Compliance, Branding & Consumer Appeal Across All Categories

Regardless of the frozen food category, brands must consider:

Regulatory Compliance

• Packaging must be FDA-approved for food contact and free from harmful chemicals like BPA.
• Labels must include storage instructions, nutritional facts, and allergen warnings.

Branding & Consumer Appeal

• Frost-resistant clear windows help consumers see the product inside.
• Bold colors and high-contrast designs stand out in the freezer aisle.
• Convenience features like resealable closures and microwave-safe packaging enhance consumer experience.

Wrap Up

Choosing the right packaging for frozen food products requires balancing durability, sustainability, compliance, and branding. Whether you’re packaging frozen meals, produce, proteins, or baked goods, the right materials and design can help ensure quality while meeting consumer expectations.

If you’re interested in learning more about frozen food packaging and exploring the best options for your brand, click the button below to request an introduction to Josh Packaging.