Frozen Asian Food Delivery

Replacing EPS with a High-Performance, Dry Ice-Compatible Packaging System

Client background

This U.S.-based brand delivers high-quality, authentic frozen Chinese bao buns, gyoza, wontons, noodles, and sauces to customers nationwide. Inspired by regional street food and classic recipes, their small-batch, handcrafted products are made with premium ingredients and flash-frozen for restaurant-quality results at home.

With four distribution centers - in California, Kansas, Atlanta, and New Jersey - they’ve built a loyal following by combining top-tier ingredients with regional authenticity, shipped direct to consumers’ homes.

Client requirements

To support frozen product delivery at scale, the client needed a packaging solution that could:

• Maintain Frozen Temperatures for 48 Hours – Rely on dry ice to hold sub-zero temperatures across the country.
• Match or Exceed EPS Performance – Without relying on traditional foam-based coolers.
• Deliver on Sustainability Goals – Move to recyclable materials while preserving thermal reliability.

Unique project challenges

Balancing Performance and Sustainability – Dumplings are particularly difficult to keep frozen, and dry ice usage adds complexity. The packaging had to withstand the challenge without sacrificing the brand’s commitment to environmental responsibility.

Thermogard solution

Thermogard delivered a solution that combined sustainability with proven dry ice performance:

• PaperShield+ 1.25” Insulation – A durable, paper-based liner engineered to perform under dry ice conditions while offering a recyclable alternative to EPS.
• Dry Ice Integration – Optimized configuration to maintain product integrity for 48 hours in transit.
• Scalable Across Distribution Centers – Deployed the solution across all four U.S. facilities for consistent performance and simplified logistics.

End result

The client achieved a major win in both sustainability and supply chain performance:

• EPS Eliminated – Prevented more than 350,000 EPS coolers annually from ending up in landfill.
• Cost Savings Delivered – Reduced packaging costs while improving consistency and handling efficiency.
• Frozen Integrity Maintained – Product remained fully frozen for 48 hours, even during peak shipping windows.

With this packaging upgrade, the client now delivers nationwide with confidence - offering premium products in a solution that’s better for their customers and the planet.

 

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