Receiving chocolate by mail is always a sweet treat! What you may not notice as you are tearing through the outer wrapping to the decadent treasure beneath, however, is how carefully the packaging was constructed to allow that chocolate to reach you in pristine condition. Sending chocolate, a fragile and occasionally finicky delicacy, is a tricky task. So, how do you ensure that your chocolate can survive a journey by ground or air? PAC Worldwide has the inside scoop. Read on for our comprehensive chocolate shipping guide and how to send chocolate without melting.

Step 1


It’s all about the weather.

Did you know that the softening point of chocolate is about 85°F (29°C) and the melting point is about 93°F (34°C)? Know the melting temperature of chocolate products then check the temperature of your chocolate destination AND the temperature of any layover to the destination. This will inform your shipping decision and the method for mailing chocolate.

Step 2

What holiday is it?

It’s not news that popular holidays can create hiccups in shipping times. If you are shipping within a holiday window, allow for additional time and package the chocolate accordingly.

Step 3

Research the shipping methods.

Whether you go by ground or by air will depend on how the chocolate is packaged. Gel packs and ice packs may be used in either service.

Step 4

Measure twice, pack once.

The size and configuration of your chocolate will help determine your packaging decision. A small, flat box of chocolate may be able to fit easily inside an insulated mailer or pouch. Chocolate covered berries, nuts, pretzels, or more delicate truffles may be better served with an insulated box liner inside a box. There should be enough space inside the packaging to fit cold packs, but not so much space that the product can be jostled and damaged. Too much empty space inside a package allows air circulation which can cause ice packs to melt faster.

Step 5

Time to pack it up!

Step 6

Oh Hurray, it’s shipping day!

Be sure that your package is being delivered to an actual address and not a PO box. Get a tracking number and do not require a signature upon delivery. This will enable the shipping service to leave the package at the destination and avoid delivery delays.

Step 7

Alert the recipient.

Recommend that the sender notify someone at the destination of the delivery time.


– For destinations above 70°F (21°C), overnight delivery is best.

– Typically, chocolate doesn’t hold up beyond 3 days in transit. Choose overnight or 2-day shipping and avoid weekend deliveries by sending pre-Thursdays.

– Dry ice can only be sent via ground shipping.

– Add a buffer lining or spacer between the chocolate and any sweat-proof ice packs or gel packs. Over cold chocolate can bloom (when sugar crystals rise to the surface and cause unsightly white spots)

– Start the packaging with a cool product. If chocolate begins a journey at a cool temperature, it requires less energy (e.g. fewer cold packs) to maintain it.

– The quicker the delivered chocolate can be retrieved and placed in a temperature controlled area, the better it will looks and taste.

Sending chocolate is an act of emotion. Since nobody wants the condition of the gift upon arrival to be the cause of any friction in a relationship, make sure the chocolate is protected on its journey. PAC Worldwide has the padded mailers, insulated box liners, and the CoolPAC reflective roll stock for shipping temperature-sensitive products in any size you need. Explore our Cold Chain Packaging inventory and create the perfect packaging for successfully shipping your sweet treats.