Dry Ice Pack Shipping Regulations: 2025 Guide

If you ship perishable goods, you must follow dry ice pack shipping regulations that control venting, labels, and weight limits. In 2025, air cargo packages can carry up to 200 kg of dry ice under PI 954, while USPS air mailpieces are capped at 5 lb. Mark UN1845, use a Class 9 label, and show net mass in kilograms on the package and air waybill. This guide turns rules into steps you can use today.

• Air rules in one page: PI 954 checkpoints and an acceptance-ready label set (UN1845, net kg).

• Mode differences: How dry ice pack shipping regulations change for air, ocean, road, and USPS.

• Right amount of coolant: A simple formula to size dry ice and avoid thaw.

• Safety & training: What handlers need—and what inspectors look for first.

• Trends: 2025 updates that speed acceptance and reduce rework.

What do dry ice pack shipping regulations require in 2025?

Short answer: Use vented packaging, mark “Dry ice” (or “Carbon dioxide, solid”) with UN1845, show net dry ice in kilograms on the package and air waybill, apply a Class 9 label, and follow IATA PI 954 for air. USPS retains a 5 lb air limit per mailpiece; U.S. DOT adds vessel-specific phrases. Stay under 200 kg per package for air cargo.

Why it matters: Dry ice sublimates into CO₂; an airtight box can bulge or rupture. Inspectors check vent paths, label placement, AWB text in kilograms, and operator variations. Mark overpacks and show the total dry-ice mass when inner marks aren’t visible. These details prevent counter rejections and delays.

How do you pass PI 954 airline acceptance the first time?

Practical checklist: Put UN1845, the proper shipping name, and net kg on the same face as a clean Class 9 label; vent the package; complete the AWB with UN1845 + proper name + number of packages + net kg per package; keep total ≤ 200 kg/package; show OVERPACK plus total kg when needed; verify operator variations before tender.

Actionable tips

• Keep critical marks together: Put UN1845, name, net kg, and Class 9 on one face when space allows.

• Write kg outside the diamond: Never write inside the Class 9 border.

• Use vented designs: Foam liners are fine—but never airtight.

Field case: A biologics exporter labeled three cartons with UN1845 and 12 kg each, placed a Class 9 on the same face, and entered “UN1845 / Carbon dioxide, solid / 3 packages × 12 kg” on the AWB. The airline accepted on first pass.

How do dry ice pack shipping regulations differ by mode?

Air cargo: Follow PI 954; show net kg on package and AWB; observe operator variations and the ≤ 200 kg/package ceiling. No DGD if dry ice cools non-DG only.
U.S. road: UN1845 is regulated primarily for air and water; ground-only legs aren’t normally hazmat under HMR, but keep strong, vented packaging.
Ocean: Apply Class 9 + UN1845 and stowage/documentation per IMDG; add U.S. vessel wording when a U.S. port is involved. USPS: Air ≤ 5 lb; surface “Surface Only” marking.

Operator variations—do they change the basics?

Yes, carriers may add placement rules, combined labels, or documentation phrasing. Treat the airline job aid as your final pre-tender checklist; it mirrors acceptance audits and reduces counter holds.

How to label and document under dry ice pack shipping regulations?

Core set (air cargo):

1. Package: “Dry ice” (or “Carbon dioxide, solid”), UN1845, net kg, shipper/consignee, Class 9.

2. AWB: UN1845 + proper name + number of packages + net kg per package.

3. Overpack: If inner marks aren’t visible, add OVERPACK and the total net kg.

Common pitfalls to avoid

• Missing kilogram units on the package or AWB.

• Writing text inside the Class 9 diamond.

• Sealing foam lids airtight; vent path is mandatory.

How much dry ice do you need—and how long will it last?

Rule of thumb: Use 5–10 lb (2.3–4.5 kg) per 24 h for standard EPS shippers; VIP shippers often need ~4–5 lb/day. Add a 20–25% buffer for delays. Round up and write the net kg on the carton.

Pro tips that save product

• Pre-chill goods to reduce sublimation.

• Pack in layers so CO₂ can vent and product stays fixed.

• Split loads to avoid heavy single boxes and improve handling.

Field case: A biologics exporter shipped insulated cartons with 18 kg dry ice each and marked UN1845 correctly. The AWB showed the net kg, and the airline cleared acceptance in minutes.

What safety and training do dry ice pack shipping regulations expect?

Hands & eyes: Use insulated gloves and eye protection to prevent contact injuries.
Air & rooms: Pack in ventilated areas; never store in sealed freezers.
Training & records: Train staff who prepare/offer shipments and keep certificates and SOPs on file; auditors often ask for them.

2-minute compliance self-check (interactive)

• I can point to a vent path in every SKU we ship.

• Our labels show UN1845 + proper name + net kg on the same face as Class 9.

• The AWB Nature & Quantity lists UN1845, name, # packages, and net kg each.

• We validate airline variations before booking.

• Overpacks show OVERPACK and total net kg when inner marks aren’t visible.

2025 developments and trends shaping dry ice pack shipping regulations

What’s new: Acceptance has become checklist-driven. PI 954 audits emphasize net kg on both package and AWB and ≤ 200 kg/package. USPS updated Pub 52 in June 2025 for clarity on air vs surface. Operators refreshed vessel markings for U.S. sea legs and published layout guides that keep UN1845, name, and Class 9 together.

Highlights at a glance

• Sharper acceptance forms: Mirror them and you’ll clear counters faster.

• Carrier label kits: Combined labels reduce placement errors.

• Ground-only clarity: Don’t introduce an unplanned air leg; it changes the rule set.

Market insight: Shippers increasingly combine phase-change materials with dry ice to cut coolant weight, while keeping frozen performance. Yet for long air exports and USPS air, kg-based entries and visible Class 9 labels remain non-negotiable.

FAQ

Do dry ice pack shipping regulations require kilograms, or can I use pounds?
Use kilograms on the package and AWB. You can note lb internally, but acceptance checks look for kg.

What’s the maximum dry ice per package for air cargo?
200 kg per package under PI 954; your airline may set lower limits.

Do I need a Shipper’s Declaration if dry ice cools non-dangerous goods?
No. Enter UN1845, proper name, number of packages, and net kg on the AWB; declare other DG normally.

Are U.S. highway-only shipments regulated the same way?
No. UN1845 is primarily air/water under the HMR. Still use strong, vented packaging.

What extra markings apply to U.S. vessel moves?
Containers need conspicuous CO₂ solid warnings; other packages carry “DO NOT STOW BELOW DECKS” phrasing.

Summary & recommendations

Bottom line: Dry ice pack shipping regulations hinge on your mode. For air, follow PI 954: venting, Class 9, UN1845, and net kg on package and AWB, ≤ 200 kg/package. USPS air keeps a 5 lb cap; surface uses “Surface Only.” U.S. vessel moves add specific phrases. Use the checklists below and standardize label placement to avoid rework.

Next steps (CTA):

1. Adopt the PI 954 acceptance checklist in your SOP.

2. Standardize labels (UN1845 + name + net kg + Class 9 on one face).

3. Size dry ice with the simple formula and add a 25% buffer.

4. Book a 15-minute compliance review with Tempk to validate your next loadout.

About Tempk

We help shippers design compliant, documented pack-outs for temperature-sensitive products. Our team aligns packaging with IATA PI 954, DOT/PHMSA, IMDG, ADR 5.5.3, and USPS Pub 52 (2025), and we provide checklists that mirror airline acceptance. Two proven advantages: fewer dockside rejections and cleaner audit trails. Talk to us before your next cold-chain shipment.