Secondary Packaging of Ice Cream: Types, Materials & Innovations

Secondary Packaging of Ice Cream: In the fast-paced, temperature-sensitive world of frozen desserts, the secondary packaging of ice cream plays a vital role in maintaining product quality, ensuring transportation efficiency, and creating brand impact. While primary packaging—like cups, cones, and tubs—directly contains the ice cream, secondary packaging adds a crucial protective and logistical layer, especially in commercial distribution, retail presentation, and bulk transportation.

In this comprehensive post, we’ll explore what secondary packaging is, its functions in the ice cream industry, the types used, materials involved, the challenges it addresses, and innovations shaping its future.

What Is Secondary Packaging of Ice Cream?

Secondary packaging refers to the layer of packaging that groups primary packaged units together. It does not come in direct contact with the product but serves important functions including:

Protection during transportation and storage
Ease of handling for distribution and logistics
Display functionality in retail environments
Information display such as branding, ingredients, or temperature instructions

In the context of ice cream, secondary packaging might include corrugated cardboard boxes, shrink-wrapped trays, cartons, or insulated containers used to group ice cream tubs, bars, or cones together in bulk.

Importance of Secondary Packaging in the Ice Cream Industry

The secondary packaging of ice cream must meet unique criteria compared to other food products, due to the highly perishable and temperature-sensitive nature of frozen desserts. Key reasons why secondary packaging is critical include:

1. Temperature Control

Ice cream requires a continuous cold chain from production to consumption. Secondary packaging must support temperature insulation and be compatible with freezing conditions without warping or weakening.

2. Product Protection

Secondary packaging shields ice cream units from:

Physical damage during transport
Contamination or exposure to light and moisture
Movement that could cause breakage or deformation of primary packages

3. Efficient Logistics

Bulk movement of ice cream products to wholesalers, retailers, or export locations relies on sturdy, stackable, and easy-to-handle secondary packaging. This helps optimize storage space in cold warehouses and transportation vehicles.

4. Retail Display and Branding

Some secondary packaging—especially those used for multipacks or club store formats—doubles as a display carton. Well-designed secondary packaging can reinforce brand identity and provide consumers with information at a glance.

Types of Secondary Packaging for Ice Cream

The type of secondary packaging chosen often depends on the type of ice cream product, volume, transportation needs, and retail format. Here are the most common formats:

1. Corrugated Cardboard Boxes

Corrugated boxes are the most widely used secondary packaging in the ice cream industry. They are:

Strong and durable
Recyclable
Customizable with printed branding and labels

Ice cream pints, bars, and cups are usually packed in these boxes in batches (e.g., 6, 12, or 24 units).

2. Shrink-Wrapped Trays

Shrink wrap is a plastic film applied over grouped ice cream items, which shrinks when heat is applied to tightly hold the items together. These are typically used for:

Ice cream bars
Multipacks
Retail club packs

The shrink wrap ensures visibility of the product while holding the items securely.

3. Display Cartons

Display cartons are designed for use directly on the retail shelf. These serve both packaging and marketing functions. Commonly used for:

Single-serve cup multipacks
Novelty ice cream items
Kids’ ice cream packs

They are often pre-perforated so they can be torn open and used as point-of-sale displays.

4. Insulated Foam Containers (for E-commerce or Specialty Delivery)

As the popularity of ice cream delivery services grows, brands are using insulated foam containers or cold chain shipping boxes for direct-to-consumer shipping. These are lined with foam or other insulating materials and are packed with dry ice or gel packs.

Materials Used in Secondary Packaging of Ice Cream

Choosing the right materials is crucial for durability, compliance, sustainability, and performance under frozen conditions. Common materials include:

1. Corrugated Fiberboard

Made from kraft paper or recycled fibers
Comes in single-wall or double-wall formats
Provides good strength-to-weight ratio

2. Plastic Shrink Film

Usually made from polyethylene or polyolefin
Transparent, flexible, and heat-shrinkable
Can be customized with prints or branding

3. Polystyrene Foam or Expanded Polyethylene

Used for thermal insulation
Lightweight and protective
Often used in e-commerce applications or specialty packaging

4. Sustainable Alternatives

Growing consumer demand for eco-friendly packaging has led to:

Corrugated boxes with biodegradable coatings
Recycled-content shrink wrap
Compostable insulation materials like molded pulp or plant fiber

Key Considerations in Secondary Packaging Design

Designing effective secondary packaging of ice cream goes beyond just putting pints in a box. Here are crucial design considerations:

1. Stackability and Stability

Packaging must be stackable to maximize space during storage and transit without crushing lower layers.

2. Moisture Resistance

Boxes and materials must withstand condensation and freezing environments without losing structural integrity.

3. Ease of Handling

Ergonomic considerations for warehouse workers, retailers, and even consumers handling multipacks.

4. Compliance with Regulations

Food safety and packaging regulations must be followed, including proper labeling and material compliance with food contact safety guidelines (especially if there’s incidental contact).

5. Brand Presentation

Colors, typography, layout, and visual cues must align with the brand’s image and market positioning.

Challenges in Secondary Packaging of Ice Cream

Secondary packaging in the ice cream sector must overcome several industry-specific challenges:

Temperature Sensitivity

Maintaining the cold chain is non-negotiable. Packaging must function well in sub-zero temperatures.

Sustainability vs. Performance

Eco-friendly materials often struggle to meet the same durability and moisture resistance standards as plastics or treated paperboard.

Supply Chain Complexity

As global supply chains evolve, ice cream is shipped longer distances. This increases the demand for strong, modular secondary packaging systems.

Space Optimization

Refrigerated transport is costly and limited. Efficient use of volume through smart packaging design is essential to reduce costs.

Innovations in Secondary Packaging of Ice Cream

To meet evolving market and environmental needs, packaging manufacturers and brands are turning to innovation. Emerging trends include:

1. Smart Packaging Technologies

Use of QR codes or NFC tags for supply chain tracking
Temperature sensors to detect cold chain breaches
Smart labels with freshness indicators

2. Sustainable Materials

Use of water-based coatings on cardboard to resist moisture
Bio-based plastics for shrink wrap
Corrugated solutions with modular inserts to eliminate plastic trays

3. Automation-Ready Packaging

With more facilities adopting robotics, secondary packaging formats are now being designed for seamless automation in packing lines.

4. Retail-Ready Packaging (RRP)

These allow boxes to convert into shelf-ready trays with minimal handling. Ideal for big-box retailers and high-volume outlets.

Case Study: Secondary Packaging Strategy of a Global Ice Cream Brand

Let’s look at Unilever’s Magnum brand as an example. For its international distribution:

Magnum uses custom-printed corrugated boxes to transport multipacks and individual bar cartons.
Each box includes batch codes, temperature storage requirements, and barcodes.
Packaging is optimized for palletization, allowing maximum stacking efficiency in frozen containers.
For e-commerce delivery, Magnum has experimented with eco-friendly cold chain shippers using recyclable insulation.

This example highlights how packaging choices must align with logistical, marketing, and sustainability goals.

The Future of Secondary Packaging in the Ice Cream Industry

The future of secondary packaging of ice cream lies in the intersection of technology, sustainability, and design efficiency. As brands adapt to changing consumer habits, regulatory pressures, and global trade patterns, expect to see:

Greater personalization in display packaging
Closed-loop packaging systems with returnable/reusable secondary packs
AI-driven logistics optimization, impacting packaging design
Compostable insulation and wraps becoming more mainstream

Sustainability will likely drive the biggest shifts, forcing companies to innovate without compromising functionality.

Conclusion: Secondary Packaging of Ice Cream

While the focus of many consumers remains on the flavors and textures of their favorite frozen treats, the secondary packaging of ice cream is an unsung hero in delivering quality, safety, and consistency. From production lines to freezer aisles and finally to the consumer’s home, it ensures that the product arrives intact, fresh, and visually appealing.

As environmental concerns rise and global logistics evolve, secondary packaging will continue to be a focal point for innovation in the ice cream industry. Brands that invest in smarter, greener, and more efficient packaging solutions will gain a significant edge—not just in cost savings, but in customer loyalty and brand perception.

Secondary Packaging of Ice Cream: Ensuring Protection, Efficiency, and Brand Value