Barbecue Boom: How Cold Chain Packaging Keeps Meat Fresh

With warmer weather sweeping across the UK and daylight stretching into the evenings, there’s one unmistakable sign that summer is here: the smell of sizzling barbecue. Once seen as an occasional weekend indulgence, barbecuing has evolved into a seasonal mainstay, integral to how Brits relax, entertain, and enjoy food outdoors.

In 2024, barbecued food was enjoyed on nearly 115 million occasions in the UK, up 9.2% year-on-year.  But with that rise comes increased demand for safe, fresh, and well-packaged ingredients, particularly meats, seafood, and other perishables that need strict temperature control.

As barbecuing becomes more frequent and spontaneous, businesses supplying fresh food, especially direct-to-consumer meat brands, retailers, and fulfilment centres, must keep pace with smarter, temperature-resilient packaging solutions. That’s where gel packs, insulation, and thermal packaging enter the frame.

The Rise of the Spontaneous Barbecue – and the Logistics That Support It

Barbecues are no longer just a “weekend event.” Over a third of UK consumers now plan BBQs just a few days in advance, and 29% take place mid-week, driven in part by hybrid work trends and flexible schedules. This shift presents a logistical challenge: more frequent, short-notice shipments of fresh goods.

For meat suppliers and food retailers, this means one thing. Cold chain reliability is no longer a luxury, but a necessity. Products need to move quickly, arrive in peak condition, and stay safe even when deliveries face unexpected delays or rising temperatures.

That’s where cold chain packaging solutions come into their own. From insulated shippers to high-performance gel packs, each component plays a crucial role in keeping meats and sides barbecue-ready when they reach the consumer.

Why Gel Packs Are Essential for the Summer Surge

Meat is the undisputed star of the barbecue, and it’s also the most vulnerable. From sausages and burgers to marinated ribs and seafood skewers, these products must be kept between 32°F and 40°F throughout the journey to maintain safety and taste.

Gel packs are the unsung heroes of this operation. Unlike dry ice, which can freeze products or present handling hazards, gel packs offer controlled, chilled environments tailored specifically for fresh, not frozen, shipping. They absorb heat slowly and steadily, ensuring your product remains cold even as outdoor temperatures rise.

Their flexibility in size and freezing point makes them especially valuable during warmer months. Whether it’s a same-day urban delivery or a 48-hour rural shipment, the right gel pack configuration can make the difference between a customer rave and a refund request.

Insulated Packaging: Creating a Portable Cold Room

Gel packs are only as effective as the packaging they work within. That’s where thermal insulation steps in. EPS foam boxes, reflective liners, and recyclable or biodegradable insulation wraps act as the first line of defence, shielding against external heat and maintaining a consistent internal environment.

During peak summer months, when delivery vehicles heat up and packages might sit in doorways under the sun, insulation plays a critical role in extending safe temperature windows. Paired with gel packs, insulated packaging creates a mobile cold room, keeping everything from lamb chops to peri-peri chicken skewers barbecue-ready on arrival.

The choice of insulation should be tailored to the route and climate. For instance, longer-distance or two-day shipments might require heavier-duty foam insulation, while local deliveries can benefit from lighter, more sustainable materials.

Meeting Consumer Expectations: Freshness, Flavour, and Responsibility

Today’s BBQ consumers are more discerning than ever. They’re not just looking for premium cuts—they expect those products to arrive fresh, chilled, and well-packaged. And with increased awareness of sustainability, they also want packaging that’s environmentally responsible.

Businesses are responding by:

• Using biodegradable insulation made from recycled denim or cornstarch.
• Offering reusable gel packs with branded instructions for refreezing.
• Including recyclable cardboard outer packaging to reduce landfill impact.

Balancing performance with sustainability is no longer optional—it’s part of building customer loyalty in a highly competitive, seasonal market.

A Hot Opportunity for Cold Chain Innovation

With the UK’s love for barbecuing continuing to grow, so too does the need for dependable thermal packaging solutions. From classic burgers to adventurous Caribbean or Indian-inspired grills, every ingredient in the BBQ box must arrive in perfect condition.

For businesses operating in this space, whether you’re a meat producer, packaging supplier, or last-mile logistics provider, summer is more than a season. It’s an opportunity. It’s a chance to prove that your packaging solutions can handle the heat, literally.

By investing in better gel packs, smarter insulation, and user-friendly packaging, you’re not just shipping products. You’re delivering peace of mind, and helping every customer enjoy a flawless BBQ experience.

Final Thought

As the UK embraces another season of sun, smoke, and spice, the barbecue isn’t just a grill, it’s a stage for quality ingredients and reliable logistics. Gel packs and thermal packaging may not be seen at the party, but behind the scenes, they’re what make it all possible.

This summer, make sure your packaging solutions are as ready for the heat as your customers are.