If you’re in the frozen food business, knowing how to package your products without using Styrofoam is no longer optional—it’s essential. Whether you’re working to meet environmental regulations, build a cleaner brand image, or cut long-term costs, switching to eco-friendly packaging is the smart move.
In this guide, we’ll walk you through step-by-step instructions for packing frozen food effectively without Styrofoam—keeping your products fresh, safe, and sustainable during transit.
🚫 Why You Should Stop Using Styrofoam Packaging
1. Styrofoam Contains Carcinogenic Substances
According to the World Health Organization (WHO), Styrofoam is unsafe for food packaging due to its benzene content—a chemical derived from petroleum that’s classified as a carcinogen.
When hot or acidic food comes in contact with Styrofoam, benzene can leach into the food, exposing your customers to harmful chemicals.
Don’t risk your consumers’ health. Switch to safe, food-grade alternatives like ALVAboard PP packaging, which is BPA-free and non-toxic.
2. It Can Damage the Nervous and Immune Systems
Styrofoam contains styrene, a compound that melts when exposed to heat and can leach into food—even during shipping.
Long-term exposure to styrene has been linked to bone marrow damage, thyroid dysfunction, and anemia. Protect your customers’ health by choosing packaging that’s scientifically safe for food contact.
3. Styrofoam is Not Truly Recyclable
Styrofoam technically can be recycled—but in practice, it rarely is. The breakdown process creates microplastics that pollute the air and oceans. Once in marine ecosystems, these particles enter the food chain and eventually end up back on our plates.
Make a better environmental choice with recyclable and reusable materials like corrugated PP plastic, which is lightweight, durable, and 100% sustainable.
🧊 How to Pack Frozen Food Without Styrofoam (Step-by-Step)
1. Start with Fully Frozen Food
Before packing, make sure your product is completely frozen—not semi-frozen or chilled. This ensures the food stays safe and preserved throughout shipping, especially for items like sausages, nuggets, or other frozen meats.
2. Use Airtight Vacuum-Sealed Packaging
Vacuum-sealed nylon bags are ideal for frozen vegetables and meat products. Before sealing and shipping:
- Ensure there’s no trapped air
- Check that the seal is tight to prevent thawing
- Keep temperatures below 0°C (32°F) before shipping
3. Pack in ALVAboard Hot & Cool Allu Foam Boxes
To maintain temperature stability during shipping, use ALVAboard Hot & Cool Allu Foam Boxes. These insulated shipping boxes are lined with aluminum and maintain hot or cold temperatures for up to 7 hours—perfect for frozen food or chilled items in transit.
4. Add Ice Gel or Dry Ice for Extra Cooling
For extra protection:
- Use ice gel packs, which are durable and long-lasting
- Consider dry ice for longer shipments; it evaporates without leaving residue
Both options help maintain sub-zero temperatures even during multi-stop deliveries.
5. Wrap with Aluminum Foil & Bubble Wrap
Before placing frozen items into the main shipping box:
- Wrap products in aluminum foil to reflect heat
- Add bubble wrap to cushion against impact
- Seal everything tightly with packaging tape
- Mark the box with a “Fragile” label to prevent stacking or mishandling
6. Place Inside ALVAboard Handle Boxes
For the outer layer, use ALVAboard Handle Boxes—a sturdy, water-resistant solution that’s reusable and easy to carry.
These boxes not only protect the product but also help elevate your brand with a more eco-conscious and premium look. Once the box is no longer needed, it can be folded flat and reused by the customer, reducing waste.
✅ ALVAboard Corrugated PP: The Future of Eco-Friendly Frozen Food Packaging
Looking to ditch Styrofoam once and for all?
ALVAboard Corrugated PP Sheets are made from food-grade polypropylene—a lightweight, waterproof, and ultra-durable material that functions like corrugated cardboard but in a plastic form.
Benefits of ALVAboard PP:
- Recyclable and reusable
- Non-toxic and BPA-free
- Moisture-resistant
- Withstands heavy loads and tough conditions
Whether you’re a small food startup or scaling to nationwide distribution, ALVAboard has the packaging solutions to help you grow sustainably.
📞 Get Expert Help with Your Frozen Food Packaging
Want to know more about the right food-grade PP plastic options for your business?
👉 Contact ALVAboard Customer Service on WhatsApp: +62 877-9310-2838
Our team is ready to help you choose the best packaging solutions to keep your food fresh and your customers happy.
🛒 Shop ALVAboard Online
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📘 Bonus: Download our free eBook “The Ultimate Guide to Food Packaging” to learn more about the latest packaging trends, compliance tips, and sustainability strategies for your food business in 2025 and beyond.
