What Is the Maximum Dry Ice Allowed per Package?

The maximum dry ice allowed per package depends on mode and operator: air cargo typically permits 200 kg under IATA PI 954, passenger baggage allows 2.5 kg, and USPS domestic air caps 5 lb. You’ll stay compliant by venting CO₂, marking UN1845, and stating net weight in kilograms. This guide gives you simple rules, a calculator, and pack‑out checklists to avoid rejection and keep products safe.

• Fast limits: The maximum dry ice allowed per package by air cargo, passenger baggage, USPS, and ground.

• Compliance essentials: Labels, markings, and venting that pass acceptance checks.

• Calculator: Convert dry ice to CO₂ gas and right‑size pack‑outs for your route and hold time.

• Carrier nuances: When operators lower the ceiling and how to plan for it.

• Real‑world tips: Vaccine kits, seafood, and e‑commerce scenarios that ship cleanly.

How is the maximum dry ice allowed per package set in 2025?

Short answer: Air cargo packages are typically limited to 200 kg under PI 954; passenger baggage is 2.5 kg (5.5 lb) per person/package with airline approval; USPS domestic air is ≤5 lb per mailpiece; ground follows 49 CFR exceptions and operator rules. Venting, “UN1845” marking, net kg, and Class 9 labels are non‑negotiable.

The maximum dry ice allowed per package reflects safety in enclosed spaces. Dry ice sublimates to CO₂; in aircraft holds this can displace oxygen and raise pressure. Operators therefore enforce per‑package caps and sometimes per‑flight totals. Ground networks rely on venting and marking rather than a single national number. Always confirm operator variations before packing.

IATA PI 954: maximum dry ice allowed per package for air cargo

Under PI 954, you can load up to 200 kg per package when packaging releases CO₂, is strong, and is correctly labeled. Airlines may set a lower ceiling by aircraft or route. For baggage, the 2.5 kg personal limit protects passengers and crew. USPS domestic air mail caps dry ice at 5 lb per piece; heavier amounts must go surface/ground.

Practical tips and suggestions

• Pharma kit (36–72 h): Use VIP shippers; aim 10–20 kg per package—well below the maximum dry ice allowed per package yet long‑lasting.

• E‑commerce frozen foods (48 h): Choose faster service + thicker EPS to stay under USPS 5 lb air cap.

• Passenger travel (seafood/meds): Pack ≤2.5 kg in a vented cooler; declare at check‑in.

Case in point: A vaccine lane reduced rejections by switching to pre‑printed PI 954 labels and logging net kg on the AWB. Acceptance time dropped, and cold excursions fell on the route’s hottest month.

How do you calculate the maximum dry ice allowed per package safely?

Core idea: 1 kg dry ice → ~541 L CO₂ gas at STP. Right‑size dry ice so expected gas fits your package’s venting capacity and the operator’s per‑package limit. The maximum dry ice allowed per package should never exceed either your vent capacity or the regulatory ceiling.

Use this simple two‑step method from the shipper’s perspective. Keep sentences short. Use round numbers.

1. Estimate gas volume: dry ice (kg) × 541 = CO₂ liters.

2. Check venting: Your packaging should safely relieve that gas over the trip. If not, reduce dry ice or upgrade insulation.

CO₂ venting, labeling, and documentation behind the limit

• Venting: Never seal liners airtight. Lids must lift or vent.

• Marking: Print “Carbon dioxide, solid (Dry ice), UN1845” and net kg on the outer box.

• Label: Apply Class 9 hazard diamond; keep the net kg outside the diamond border.

• Docs: For air cargo, include UN1845 and net kg on the air waybill. Some cases require a DG declaration.

Which carriers and services change the maximum dry ice allowed per package?

Airlines and integrators can set lower caps than PI 954. Expect 2.5–10 kg caps in some express networks for standard parcel air services. Passenger baggage holds at 2.5 kg per person/package with airline approval. USPS caps 5 lb for domestic air; heavier pieces must move surface/ground with “Surface Mail Only” marking. Ground carriers will carry >2.5 kg per package under additional rules—confirm acceptance first.

USPS, passenger baggage, and ground exceptions—how to plan

• USPS air (≤5 lb): Upgrade insulation or compress transit time to stay under the cap.

• Passenger (2.5 kg): Declare, mark, and use vented containers. For more volume, ship cargo.

• Ground >2.5 kg: Apply full markings and ensure driver awareness in enclosed vehicles.

2025 developments and trends shaping the maximum dry ice allowed per package

Trend overview: In 2025, cold chain programs focus on optimal—not maximal—dry ice. Smart CO₂ sensors, automated venting, and hybrid PCM + dry ice pack‑outs reduce risk, re‑ice events, and emissions. Operators are tightening per‑flight CO₂ load planning in hot seasons and animal‑carriage routes. Update SOPs with current label formats and bigger type for net kg readability.

What’s new (at a glance)

• Smart CO₂ monitoring: Real‑time gas + temperature alerts cut surprise rejections.

• Hybrid pack‑outs: PCM + modest dry ice extends hold time with less total CO₂.

• Acceptance UX: Carriers emphasize pre‑booking quantity checks and clear label placement.

Market insight: Biologics and gene therapies keep demand high. Reusable VIP systems and route‑specific pack‑outs reduce total dry ice while maintaining deep‑frozen lanes. Teams that model sublimation against per‑hold caps avoid last‑minute splits and delays.

Frequently Asked Questions

Q1. What is the maximum dry ice allowed per package on air cargo?
Typically 200 kg under PI 954, but operators can set lower numbers. Book early and confirm.

Q2. What is the maximum dry ice allowed per package in passenger baggage?
2.5 kg (5.5 lb) per person/package with airline approval in a vented container.

Q3. What is the maximum dry ice allowed per package in USPS domestic air?
5 lb per mailpiece. Heavier pieces must travel surface/ground and be marked accordingly.

Q4. Can I exceed 2.5 kg on ground?
Yes, but you lose the small‑quantity exception and must meet added hazmat and carrier rules.

Q5. Where do I write the net weight?
On the outer box in kilograms, not inside the Class 9 diamond.

Q6. Does form (pellets vs blocks) change the maximum dry ice allowed per package?
No—the cap is net mass. Pellets sublimate faster, so plan slightly higher loads for the same hold time.

Q7. Do I need a Shipper’s Declaration?
Sometimes. For non‑DG products cooled by dry ice, you often only note UN1845 and net kg on the AWB. Check your operator’s rules.

Summary and Recommendations

Key points: The maximum dry ice allowed per package is 200 kg for air cargo (typically), 2.5 kg for passenger baggage, and 5 lb for USPS air. Always vent CO₂, mark UN1845 and net kg, and confirm operator variations. Use VIP or hybrid pack‑outs to lower required mass and stay well below caps.

Next steps:

1. Map your mode and route; apply the correct cap.

2. Use the estimator above to size dry ice and validate venting.

3. Print compliant labels and pre‑book quantities with the carrier.

4. Add CO₂ and temperature logging to every high‑value lane.
   CTA: Need a PI‑954‑ready label set and pack‑out checklist? Talk to Tempk today.

About Tempk

We design and validate IATA‑compliant dry‑ice and PCM systems for biopharma, food, and specialty logistics. Our engineers combine packaging science with airline acceptance know‑how to cut rejections and re‑ice costs. Clients see fewer delays and more stable temperatures thanks to right‑sized dry ice and better venting.

Let’s optimize your route: Request a lane‑specific pack‑out and labeling template from our team.