Sending Packages with Dry Ice: 2025 Rules & How‑To
Sending packages with dry ice is straightforward when you mark UN1845, show the net kilograms, apply the Class 9 label, and use packaging that vents CO₂. Air cargo allows up to 200 kg per package, while USPS domestic air caps dry ice at 5 lb per mailpiece; plan 5–10 lb per 24 hours of transit for sizing.
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What matters most for compliance and safety when sending packages with dry ice
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How to label and document (UN1845, net kg, Class 9) for sending packages with dry ice
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How much dry ice you need, using a simple daily sublimation estimator
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What USPS, FedEx, and UPS check, including overpack totals and air waybill entries
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2025 updates and trends, plus a mini self‑assessment and calculator
What matters most when sending packages with dry ice?
Short answer: Use vented packaging, print “Dry Ice/Carbon dioxide, solid” with UN1845, add net weight in kilograms, and apply the Class 9 label. If dry ice only cools nondangerous goods, a Shipper’s Declaration isn’t required, but airline acceptance checklists still apply. Aim for first‑pass acceptance with a pre‑tender self‑check.
Why it works: Vented packaging prevents pressure build‑up as dry ice turns to gas. Printing UN1845 and net kg aligns your box with operator checklists and speeds counter handling. Most refusals come from missing net‑kg, poor label placement, or forgetting overpack totals. Think of your label block as the box’s “passport.” When it’s complete, you pass quickly.
Label and marking basics for UN1845 dry ice shipments
Put the proper shipping name and UN1845 on a vertical side, keep the Class 9 diamond nearby, and state net kilograms clearly outside the diamond. Add shipper/consignee details and ensure the box vents. For air, remember the 200‑kg/package ceiling; for USPS domestic air, keep each mailpiece ≤5 lb of dry ice.
| Compliance quick sheet | Requirement | Limit/Note | What it means for you |
|---|---|---|---|
| Marking | “Dry Ice/Carbon dioxide, solid” + UN1845 | English | Use a clear, legible text block |
| Weight | Net dry ice in kg | Outside Class 9 | Convert lb→kg before printing |
| Hazard | Class 9 label | Same face when possible | Improves handler visibility |
| Venting | Not airtight | Required | Avoid sealed inner coolers |
| Limits | 200 kg/package (air); USPS air ≤5 lb | Ceiling vs. mail cap | Plan lanes and breakouts accordingly |
Practical tips and suggestions
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Air lanes: Print a single label block with UN1845, proper name, net kg, Class 9; photograph every carton before tender.
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Overpacks: Add the total net kg of dry ice on the overpack; operators look for it.
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USPS: For domestic air, ≤5 lb per mailpiece with venting; for more coolant, use parcel carriers or split pieces.
Real example: A diagnostics lab embedded the 2025 dry‑ice acceptance checklist into pick/pack. First‑pass acceptance climbed to ~100% and dock dwell fell by 12 minutes per consignment.
How to label and document when sending packages with dry ice?
Direct answer: Print UN1845, the proper shipping name, net kg, and apply Class 9. Enter dry‑ice net kg on the air waybill where required. Use the latest airline acceptance checklist as your pre‑flight. No Shipper’s Declaration is needed when dry ice cools nondangerous goods.
Details that prevent refusals: FedEx/UPS job aids mirror IATA PI 954. They call out overpack totals, text size, and keeping net kg outside the diamond. Standardize one template so every package looks the same across shifts and sites. Align WMS fields so AWB entries auto‑populate.
Overpacks, AWBs, and common pitfalls
Overpacks must show the total net kilograms of dry ice, not just inner box amounts. Keep “Dry Ice/UN1845/net kg” visible on the outermost layer. On AWBs, list dry ice per carrier instructions; many operators scan for “kg,” not “lb.” These small details reduce rework at the counter.
How much do you need when sending packages with dry ice?
Rule of thumb: Plan ~5–10 lb per 24 hours in a quality insulated shipper, then adjust for season, route, and openings. Validate with a data logger on pilot runs before locking your SOP.
Dry‑ice mass estimator (start point—validate in your lane)
| Duration | Typical ambient | Starting estimate | What it means for you |
|---|---|---|---|
| 24 h | 20–25 °C | 5–10 lb | Small parcels and short hops |
| 48 h | 20–30 °C | 10–20 lb | Add margin for handoffs |
| 72 h | 25–35 °C | 15–30 lb | Consider VIP or re‑icing points |
Pro tip: Place product securely, separate it from dry ice with cardboard, and fill voids to slow sublimation. Log internal temp vs. ambient on first shipments to calibrate your pack‑out.
What do USPS, FedEx, and UPS check when sending packages with dry ice?
USPS (domestic air): Package must vent CO₂, carry “Dry Ice/Carbon dioxide, solid,” UN1845, and net kg. ≤5 lb of dry ice per mailpiece. No international mail for perishables with dry ice.
FedEx/UPS (air): Follow PI 954 marks and labels; no Shipper’s Declaration when dry ice is the only DG. Show net kg on package and AWB; overpacks must show total net kg. Standardize label placement and text size.
Air limits: 200 kg per package is the upper bound for air cargo; travelers may carry up to 2.5 kg of dry ice in baggage if vented and marked. Operators can publish compartment caps—check before consolidating.
Safety and ventilation when sending packages with dry ice
Bottom line: Dry ice becomes CO₂ gas. Work in ventilated spaces, avoid airtight containers, and wear insulated gloves and eye protection. OSHA’s 8‑hour TWA is 5,000 ppm; NIOSH IDLH is 40,000 ppm—design prep rooms accordingly.
CO₂ exposure quick sheet
| Limit / Guidance | Value | What to do | For you |
|---|---|---|---|
| OSHA PEL (8‑hr TWA) | 5,000 ppm | Vent rooms; rotate tasks | Reduce exposure risk |
| NIOSH STEL | 30,000 ppm | Minimize time near open bins | Manage peaks |
| NIOSH IDLH | 40,000 ppm | Treat confined spaces with caution | Never seal gas |
Quick checks: Vent the package and vehicle cargo area; train teams on CO₂ symptoms; use a CO₂ meter in enclosed prep rooms where practical.
2025 updates and trends in sending packages with dry ice
Trend overview: Airline acceptance forms now mirror PI 954 more tightly, emphasizing net‑kg visibility and overpack totals. USPS continues the simple ≤5 lb air cap for domestic mailpieces. Many networks standardize the 5–10 lb/day planning rule and adopt VIP insulation or hybrid PCM to stretch hold time and reduce coolant mass.
Latest progress at a glance
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Standardized acceptance: Checklists reduce counter friction and refusals.
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Operator limits: Some carriers publish aircraft/compartment caps—plan multi‑carton loads.
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Hybrid packing: Combining dry ice + VIP/PCM trims coolant while preserving cold life.
Market insight: E‑commerce perishables and specialty pharma keep volumes high. Teams increasingly pair data loggers with dry‑ice lanes to document performance and defend SLAs.
Frequently Asked Questions
Do I need a Shipper’s Declaration when sending packages with dry ice?
Usually no when dry ice cools nondangerous goods. Use correct marks/labels and the current acceptance checklist.
What is the maximum dry ice per package by air?
200 kg per package under PI 954; typical parcels are far below this ceiling.
How much dry ice should I plan per day?
Start with 5–10 lb per 24 hours, then validate in your own shipper and lane.
Can I send dry ice with USPS?
Yes, for domestic air with ≤5 lb per mailpiece and proper venting/marking. No international perishables with dry ice.
Where do the labels go?
Place the Class 9 diamond and the UN1845/“Dry Ice”/net kg text block on a vertical side with clear line of sight.
Summary & next steps
Key takeaways: Sending packages with dry ice comes down to venting, UN1845 + proper name, net kg, Class 9, and a quick acceptance self‑check. Plan 5–10 lb/day, mark overpack totals, and align with USPS ≤5 lb for domestic air. Train teams on CO₂ safety and standardize one label template.
Action plan:
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Standardize a label block (UN1845/name/net kg/Class 9).
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Embed the 2025 acceptance checklist at pack‑out.
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Size dry ice with the estimator; validate via loggers.
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For USPS air, split to ≤5 lb or use parcel carriers.
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Call to action: Get Tempk’s ready‑to‑use SOP + label kit and ship with confidence.
About Tempk
We help brands and labs master sending packages with dry ice—from compliant label templates and acceptance audits to SOPs and lane validation. Our playbooks cut exceptions and dock dwell while keeping teams safe. Two concrete advantages: pre‑tender checklists that mirror airline forms, and pack‑out calculators tuned to your lanes.
CTA: Talk to Tempk’s specialists for a tailored PI 954/USPS checklist and pack‑out calculator today.
