Dry Ice Pack for Shipping Food (2025): Safe, Compliant & Cost‑Smart

• What dry ice packing is—and why it works

• How much dry ice you really need (calculator + examples)

• Step‑by‑step pack‑out that passes audits

• 2025 regulations cheat sheet (IATA/DOT/USPS)

• Safety: PPE, ventilation & CO₂ exposure

• Dry ice vs. gel packs vs. PCMs/VIPs

• Food‑specific tips: meat, ice cream, seafood

• FAQs

What dry ice packing is—and why it works

Dry ice is solid CO₂ that sublimates at –78.5 °C (–109.3 °F), so it keeps loads frozen without meltwater. As it sublimates, it displaces air with dense CO₂ gas; packaging must be able to vent.

Key physics for planners

• Gas volume: ~8.8 ft³ CO₂ per lb of dry ice; sublimation rate depends on format (pellet vs. block), insulation, and ambient profile.

• Top‑loading helps: CO₂ sinks, so placing dry ice above the payload improves envelope temperature uniformity.

How much dry ice you really need

Rule‑of‑thumb starting point: 5–10 lb per 24 h in a typical insulated shipper, plus one extra day as a delay buffer; then validate with a data logger on your lane.

Lane‑aware calculator (pragmatic, not regulatory)
Start load = (5–10 lb × hours/24) × Insulation factor × Ambient factor + one 24 h base load as buffer.

• Insulation factor: VIP × 0.7 · EPS (1–1.5″) × 1.0 · Minimal insulation × 1.3

• Ambient factor: Mild (<25 °C) × 1.0 · Hot (25–35 °C) × 1.2 · Very hot (>35 °C) × 1.4
  Example (48 h, EPS, ~30 °C): (5–10 lb × 2)×1.0×1.2 + (5–10 lb) ≈ 17–34 lb. Validate before scale‑up.

Why this range works: It reflects widely cited operational guidance and real‑world thermal behavior; still, validate on your specific shipper and lane.

Step‑by‑step pack‑out that passes audits

1. Choose the right shipper. EPS for cost; VIP for long lanes/weight savings—ideally validated to ISTA 7E (72/144 h) with Standard 20 documentation.

2. Pre‑chill payload. Freeze to ≤0 °F (–18 °C) before packing for frozen shipments.

3. Line & segregate. Keep sensitive items off direct contact with dry ice.

4. Add dry ice (top‑load preferred) and fill voids to reduce air exchange (slower sublimation).

5. Ensure venting. Never seal airtight; permit CO₂ release. (Required by DOT for air/water; also in IATA PI 954.)

6. Close, then mark & label:

   • Proper shipping name: “Carbon dioxide, solid” or “Dry ice”, UN 1845

   • Net weight of dry ice in kilograms on each package

   • Class 9 hazard label (diamond ≥100 mm)

7. Docs: For air consignments with only dry ice + non‑dangerous goods, a Shipper’s Declaration is not required; include the required text on the Air Waybill. Always honor state/operator variations.

2025 regulations cheat sheet (quick‑ref)

• IATA DGR 66th (effective Jan 1, 2025):

  • ≤200 kg dry ice per package by air; PI 954 requires vented packaging; AWB must list UN1845, proper name, number of packages, and net kg. Operator variations apply.

• U.S. DOT (49 CFR 173.217):

  • Packaging must permit CO₂ release to avoid rupture; mark net mass externally for aircraft; shipper must arrange with operator.

  • 2.5 kg (5.5 lb) per package exception for certain air shipments if marked as specified (still vent!).

• USPS (Postal Explorer):

  • International mail: prohibited.

  • Domestic air: ≤5 lb of dry ice per mailpiece; follow Packaging Instruction 9A.

• Carrier guides (example FedEx):

  • Class 9 label ≥100×100 mm; UN 1845 text and net kg required; many carriers echo ≤200 kg per package consistent with IATA.

Practical takeaway: Bookings sometimes require declaring net kg at time of tender to ensure aircraft CO₂ limits aren’t exceeded (operator variations).

Safety: PPE, ventilation & CO₂ exposure

• People: Use insulated gloves and eye protection; handle in well‑ventilated spaces.

• Exposure limits: OSHA PEL = 5,000 ppm (8‑h TWA); NIOSH STEL = 30,000 ppm (15 min). Consider CO₂ monitors in pack rooms, coolers, and vehicles.

• Vent awareness: 1 lb → ~8.8 ft³ CO₂; staging many boxes in a small room can spike CO₂—use exhaust, open doors, and limit batch size.

Dry ice vs. gel packs vs. PCMs/VIPs (which to choose?)

• Dry ice: Deep‑frozen/ultracold; strict marks/labels; heavier than some VIP+PCM combos.

• Gel packs (water‑based): Best for 2–8 °C; simpler compliance; possible condensate/leaks.

• PCMs + VIP shippers: Tune setpoints (e.g., –21 °C or +5 °C); validated VIP systems cut refrigerant mass and total freight on 72–144 h lanes.

<Food‑specific tips (meat, ice cream, seafood)

• Ice cream: Aim to keep < –20 °C end‑to‑end; prefer VIP on 72 h lanes; top‑load dry ice; minimize headspace.

• Meat/seafood: Pre‑freeze hard; use liners to avoid direct contact; consider pellets + blocks for faster start and longer tail.

• Ops: Weekends add risk—ship early week and add a full‑day buffer.

FAQs

How much dry ice for 48 h?
Start with 10–20 lb depending on shipper and lane, plus a 24‑h buffer; verify with pilots and a data logger.

Do I need a Shipper’s Declaration for dry ice?
If dry ice is the only dangerous good and it’s cooling non‑dangerous goods by air, no Shipper’s Declaration is required; include the proper AWB text and labels. Carrier variations may add requirements.

Is dry ice allowed in international mail?
No. USPS prohibits dry ice in international mail; domestic air is ≤5 lb with Packaging Instruction 9A.

Can I seal dry ice inside a bag?
No—packaging must vent; never airtight.

What are the safe exposure limits?
OSHA 5,000 ppm (TWA); NIOSH 30,000 ppm (STEL). Use monitors in small rooms