Insights from Stephanie Berwick, founder of Pastazerts

Launching frozen isn’t just about keeping things cold.

It’s a whole different business with unique costs, timelines, and rules, from packaging that pops behind foggy freezer doors to cold-chain logistics that can make or break your margin.

Below, we break down what to expect, what to avoid, and how to build a brand that actually works in the freezer aisle.

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For founders who are:

• Launching or scaling a frozen food brand
• Exploring a frozen line extension
• Preparing to pitch frozen products to retail buyers </aside>

Why frozen changes everything

Launching a frozen product isn’t just about keeping it cold. It means operating with a totally different set of rules, costs, and timelines.

Key challenges to plan for:

• Cold-chain logistics: You need reliable, temperature-controlled transport at every step, from production to shelf.
• Higher production costs: Smaller runs, limited co-manufacturers, and specialized equipment often mean higher minimums and less flexibility.
• Storage + shipping fees: Frozen storage is priced at a premium, and insulated shipping (especially for DTC) adds extra costs per unit.
• Tighter margins: Distributors often take a bigger cut on frozen SKUs. That means you need to model your margins early — and build in buffer.
• Smaller margin for error: One break in the supply chain can result in a spoiled product and unsatisfied customer.