A Guide to Shipping Chocolate

Tips and best practices for packaging and shipping chocolate products.

While the winter months are long and cold, they do have positive implications when it comes to shipping chocolate. Colder weather means colder shipping temperatures, which makes it easier and cheaper to prevent chocolate from melting while in transit.

Shipping chocolate using web fulfillment, including FedEx or UPS Ground, comes with certain difficulties, and various considerations must be made to prevent goods from spoiling while on their way to your customers. Questions you should ask include:

Key Considerations for Shipping Chocolate

Shipping chocolate for web fulfillment, including FedEx or UPS Ground, comes with certain difficulties, and various considerations must be made to prevent goods from being damaged while on their way to your customers. Here are some key questions to consider when shipping chocolate:

  1. How long can my chocolates stay in transit?
    Some companies will ship chocolate overnight to avoid melting and blooming. Keeping transit times short is a good strategy but has grown to be too expensive recently.
    These companies will use a 24 hour insulated box liner and gel packs to stretch out the transit time or combat warmer weather.Shipping chocolate using 2-3 day shipping is possible with thicker insulators like our EcoLiner and CelluLiner. Adding gel packs to thicker insulated box liners will improve the overall performance of the packout.
  2. Check the weather forecast for your specific route of shipping. Developing historical data of temperatures along routes can help you identify situations where your shipping methods fail.
    1. Building out seasonal temperature profiles for testing  common transits for shipping chocolate.(requires thermal testing chambers.
    2. A winter shipment of chocolate will call for a thinner liner (plastic bubble and metalized film)  and little to no ice packs depending on the route and shipping duration.
    3. A summer shipment or an extreme weather period might require a different pack out: more gel packs, humidity protection, foam, fiber insulator at least 1” thick.
  3. Temperature control is the key to shipping chocolate. You have to make sure the container’s internal temperature is not too cold for too long to prevent blooming. And you also have to ensure your chocolates don’t get too hot and melt.

    The way to get to the perfect temperature for shipping chocolate is to find the perfect balance of gel packs, insulator and box size. Which is why we recommend talking to one of our experts before committing to large orders. We even send out insulated box liner samples.
  4. Lastly, you’ll want to think about your pack-out, or the way you arrange items in your box. Reducing the moisture collected inside your package is key to preventing damage from condensation. Generally, less air space is a best practice.

    If your operation is large enough we recommend using our sweat proof gel packs, but craftier solutions also work, like wrapping the chocolate box in bubble wrap/paper to prevent condensation damage or putting the gel pack in a plastic bag.
    In terms of ice pack placement, we’ve seen companies put one ice pack on top and one on bottom like a sandwich. We’re partial to putting the cold packs on top and letting the cold air sink to the bottom.

Chocolate being shipped inside a PopupLiner Box Liner

Chocolate being shipped inside a PopupLiner Box Liner

If you want to prevent your products from melting in transit while also maintaining a cost-efficient shipping process, it is important to have a clear understanding of the above factors.

Melting

The melting temperature of chocolate varies depending on its composition. Generally, the melting points are as follows:

  1. Dark Chocolate: Melts at around 86°F to 90°F (30°C to 32°C).
  2. Milk Chocolate: Melts at around 84°F to 88°F (29°C to 31°C).
  3. White Chocolate: Melts at around 82°F to 84°F (28°C to 29°C).

The temperatures listed above are not definitive, the specific proportions of cocoa butter, milk solids and sugars are specific to your chocolate and knowing your particular chocolate’s melting point is a prerequisite to shipping chocolate mastery.

Because these temperatures are relatively low for a box just sitting on a truck during the summer companies use an insulated liner to provide some protection on 24 hour shipments and they’ll use a combination of liner and gel packs for longer transport times or hotter weather.

Blooming

Blooming in chocolate is the dreadful “white stuff” on “old chocolate” or refrigerated chocolate. Blooming occurs due to temperature fluctuations that force fats or sugars to the top of the chocolate.

  1. Fat Bloom: This occurs when chocolate is exposed to temperatures above 75°F (24°C) and then cooled. The cocoa butter melts and recrystallizes on the surface, creating a whitish or grayish film.
  2. Sugar Bloom: This happens when chocolate is exposed to moisture, causing the sugar to dissolve and then recrystallize. It can occur at temperatures above 60°F (15°C) if the chocolate is stored in a humid environment. This is particularly important when using gel packs as the condensation from the gel packs will result in moisture in the box. We offer a sweat proof gel pack that is condensation resistant.

To prevent blooming, it is important to keep chocolate at a consistent, cool temperature, ideally between 55°F and 68°F (13°C and 20°C), and in a low-humidity environment. Proper packaging and storage conditions during shipping maintain the quality and appearance of chocolate.  

Packaging Your Chocolate

When preparing to ship chocolate products, make sure you have all the required materials to provide sufficient protection.

Required Materials:

  1. Insulated box liner for chocolates, you’ll need an insulated liner to protect your chocolate from the elements. Here are some solutions we provide.
    1. CooLiner- A reflective insulated box liner. A foil backing combined with plastic bubbles makes this type of insulation liner highly effective for providing temperature control for over 24 hours. This advanced material in bag form, lines the inside of your insulated shipping box to provide both conductive and reflective insulation.
    2. CelluLiner- a thick all paper box liner perfect for keeping chocolates cold for over 48 hours and providing an easy curbside recyclable insulated box liner your customer can just place in their recycle bin after opening up your delivery.
    3. EcoLiner: Our insulated box liner made from recycled textile materials and comes in variable thicknesses capable of keeping chocolate cold for over 48 hours.
  2. Corrugated box for liner, chocolates and refrigerant.
    Cold Packs for Shipping Chocolate
    Cold packs help to keep your chocolate shipments colder for longer
  3. Frozen refrigerant cold packs/gel packs. While the insulated box liners help to keep temperatures low for up to 48 hours, cold packs can be added to keep your shipments cold for even longer durations. The quantity of gel packs required depends on the total transit time and temperature of the transit location. Sweat-proof ice packs are available if you are concerned about condensation ‘sweating’ onto your products.
  4. Additional packaging materials like kraft paper or bubble wrap  might be required to ensure your box is packed properly and chocolate shipments are kept securely in place.

How to Pack Chocolate for Shipping

Shipping chocolate requires careful preparation to ensure it holds its form and flavor during transit. Here’s a step-by-step guide to help you pack chocolate for shipping effectively:

Preparing the Chocolate

  1. Work with Cold, Clean Hands: Chocolate softens at temperatures lower than the human body. Run your hands under cold water before packaging to prevent melting.
  2. Store in a fridge/Wine Cooler: Before shipping, keep your chocolates in a wine cooler to cool them without causing sugar bloom. Wine coolers operate between 45°F and 67°F, ideal for maintaining the chocolate’s integrity.

The Packaging Process

  1. Use a Specialty Chocolate Box: Place your chocolates in a dedicated chocolate box. This is your chance to present your chocolates and turn a handful of chocolates in an “assortment.” The experience of opening a box of chocolate is akin to life itself, or so mama said.
  2. Build the Shipping Box for Chocolate:

    It’s important to determine your box size. Your operations team will calculate total cost of shipping materials and expenses against the price of the chocolate. In order to get there you’ll need to decide on the internal dimensions of your box and what shipping method you’re looking to use.

    • Your box’s internal dimensions are the space inside of your corrugated box. We don’t want to leave empty space here. The denser the package the better it is for the lifespan of the refrigerant and by extension your chocolates.Calculate your internal dimensions, this is the size of your dedicated chocolate box, perhaps stacked two high.
    • Determine your packout. Are you stacking boxes of chocolate on top of each other? Is it a single box of chocolate? Are you shipping out cases of chocolates to stores? Keep the length, width and height of that pack out in mind.
    • Add a ½” to 1-½” to the top, to accommodate for frozen gel packs if needed.
    • Depending on transport times, you’ll have different thicknesses to add to your final box size:
      • Liners for shipping chocolate overnight or under 24 hours
        Leave a half inch on all dimensions (LxWxH) for CooLiner metalized film and bubble liner
      • Liners for shipping chocolate 2 day or 3 day ground shipping- Over 24 hours.
        Leave one to 3 inches on all dimensions for the recommended liner. Need an insulated box liner recommendation?
  1. Add Gel Packs (if necessary): Depending on the time of year, destination, and transit distance, decide how many cold packs you need:
        • Place a cold pack at the bottom of the shipping container, wrapped in a resealable plastic food bag to prevent condensation.
        • You can also purchase sweat proof fiber gel packs to reduce condensation and overall humidity within the package.
  1. Insert the Chocolate Box: Place the chocolate box into the shipping container. Surround it with cold packs if needed and fill any remaining gaps with packing materials. Reducing the empty space increases the effectiveness of the liner and refrigerant keeping your chocolates cooler for longer
  2. Secure the Shipping Box: Tape all seams of the shipping box to reduce warm air penetration.
  3. Add Shipping Labels: Your chocolates are now ready for shipment.

Related Products

PopupLiner Box Liner

Available in custom sizes, PopupLiner box liners are high-performance thermal liners that effectively protect your chocolate shipments for up to 72 hours.

Chocolate Shipping Boxes
EcoLiner Box Liner

An Earth-friendly insulation liner that protects against extreme ambient temperatures, the EcoLiner is 75% more space-efficent than molded coolers.

Tips for Shipping Chocolate

  1. Know Your Chocolate’s Melting Temperature: Different chocolates have different melting points based on their ingredients. Dedicate some time figuring out your chocolate’s melting point.
  2. Pre-cool Your Products: Store chocolate in a cool place before packaging.
  3. Choose Optimal Shipping Times: Ship early in the week to avoid weekend delays and ship in the latter half of the day to avoid having your boxes sitting in the heat.
  4. Consider Seasonal Variations: Adjust shipping methods based on the season and destination climate.
    1. The route to Oregon from Chicago in August has a different temperature set than that from Louisiana to Arizona
    2. Through a series of testing determine your best configuration of gel packs and thermal insulators.
  5. Select the Right Packaging: Use insulated box liners, pouches, or pallet shippers based on your needs.
    1. EcoLiner pouches
    2. CelluLiner pouches
    3. Insulated Pallet Covers
  6. Provide Accurate Delivery Times: Ensure the recipient is available to receive and refrigerate the chocolate immediately upon arrival.

Custom Packaging Solutions

IPC offers tailored insulated packaging solutions for all your chocolate shipping needs. Whether you’re shipping single units or bulk orders, we provide efficient and cost-effective options.

This advice applies to all types of chocolate shipments, whether you’re looking to ship chocolate-covered strawberries, gourmet chocolate bars, or something else. Know your processes and take precautions to ensure a smooth and successful delivery every time.

IPC can provide custom insulated packaging solutions to any chocolate-shipping requirement. Whether you are sending single units to consumers, or sending bulk shipments to your business customers, we help you to do it quickly, efficiently, and cheaply. Get in touch today for a custom quote.

Related Products

PopupLiner Box Liner

Available in custom sizes, PopupLiner box liners are high-performance thermal liners that effectively protect your chocolate shipments for up to 72 hours.

Chocolate Shipping Boxes
EcoLiner Box Liner

An Earth-friendly insulation liner that protects against extreme ambient temperatures, the EcoLiner is 75% more space-efficent than molded coolers.

Insulated Shipping

Call 310-638-0900

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