Keeping temperature sensitive goods safe during transport isn’t just about putting ice in a box—it’s about choosing the right refrigerant and packaging. Dry ice bags and dry ice packs are now central to modern cold chain logistics because they provide ultra low temperatures without adding moisture. As new materials and smart sensors emerge, these solutions continue to evolve. In this guide you’ll learn how dry ice bags and packs work, why they’re crucial for food, pharmaceuticals and e commerce deliveries, and what innovations are reshaping cold chain operations in 2025.
Understand what dry ice bags and dry ice packs are – including how they’re made and why they’re different from traditional gel packs.
Compare performance, cost and sustainability of dry ice, premium dry ice packs, PCM bricks and gel packs.
Follow safety and regulatory guidelines to package dry ice properly and avoid hazards.
Size and handle dry ice packs effectively using practical formulas and tips.
Explore 2025 innovations and trends like IoT sensors, blockchain traceability and portable cryogenic freezers.
What Are Dry Ice Bags and Dry Ice Packs?
Dry ice bags are insulated shipping bags designed to hold dry ice or dry ice packs. They typically feature multiple layers of insulation and a leak proof outer shell to prevent condensation and CO₂ vapor from escaping. Dry ice packs, also called dry type ice packs, are portable refrigerant modules made from Super Absorbent Polymer (SAP) and non woven or permeable films that absorb water, form a gel and then freeze. Unlike frozen water, dry ice packs do not create melt water; instead, the gel inside slowly releases ultra cold temperatures as it sublimates.
How Dry Ice Packs Work
Dry ice packs usually consist of three layers: an outer layer of polyethylene or non woven fabric for strength and permeability, a SAP layer that absorbs water and forms a gel, and a leak proof composite film to prevent leaks. To activate a pack, you immerse it in water for several minutes until the SAP absorbs water and swells. After freezing, the gel slowly releases its stored cold energy. Because the packs remain somewhat flexible after freezing, they can conform to the shape of the products, improving cooling efficiency.
| Component | Function | Benefit to You |
| Outer layer (PE or non woven) | Provides permeability and structural strength | Prevents tearing and allows CO₂ vapor to escape safely |
| SAP layer | Absorbs and locks in water to form a stable gel | Creates long lasting cold without melt water |
| Leak proof film | Adds a safety barrier to contain the gel | Minimizes risk of leaks during transport |
Dry Ice Bags vs Dry Ice Packs
Dry ice bags and dry ice packs complement each other but serve different purposes. The bag acts as the insulated container, often made from multi layer materials like high density polyethylene (HDPE) and reflective foil. It holds the refrigerant and cargo, preventing heat ingress. A dry ice pack is the refrigerant itself. Modern premium packs use HDPE or EVA shells around a PCM matrix and insulated liner to hold –78.5 °C for 72–120 hours, whereas ordinary dry ice typically lasts 24–48 hours. Because premium packs are reusable for 100–200 cycles, they significantly reduce waste and total shipping cost.
Why Choose Dry Ice Bags and Packs for Cold Chain Shipping?
Superior Temperature Control and Flexibility
Traditional gel packs can become rigid when frozen, and their cooling performance degrades quickly. Dry ice packs remain flexible, allowing them to conform to products and maintain consistent temperatures. They’re lightweight and compact, saving storage space. Premium designs leverage composite shells, PCM matrices and insulated liners, giving them five times longer hold time than single use gel or dry ice packs. For vaccines and biologics requiring ultra cold conditions, dry ice packs can maintain –78.5 °C for multiple days.
Safety and Environmental Friendliness
The base materials in dry ice packs—non toxic SAP and water—do not contaminate products, and any leakage poses minimal environmental risk. Premium packs integrate safety features such as enclosed shells that prevent direct contact with solid CO₂, reducing the risk of cold burns. Because they are reusable, premium packs cut packaging waste and carbon footprint; some solutions such as the Marken InfiniDI reduce dry ice use by 50 % and cut waste by up to 90 %.
Cost Effectiveness and Reusability
Although dry ice has a low per shipment cost, it must be replenished for each use and is classified as hazardous. Premium dry ice packs require a higher upfront investment but can be reused dozens or even hundreds of times, lowering total cost per shipment. Compared with gel packs or –21 °C PCM bricks, premium packs provide longer hold times and more reuse cycles. According to market research, the global reusable icepacks market was around $1.2 billion in 2023 and is expected to reach $2.5 billion by 2032, driven by health, food and sustainability trends.
Safety and Regulatory Considerations
Hazards of Dry Ice
Dry ice is the solid form of carbon dioxide. At approximately –110 °F (–78.5 °C), it sublimates directly into gas, so it keeps products cold without creating liquid water. However, dry ice itself is hazardous: it can cause frostbite on contact and can displace oxygen in confined spaces, leading to asphyxiation. Packages that don’t allow proper venting may explode from CO₂ buildup.
Regulations for Air and Ground Transport
Dry ice is regulated as UN 1845 and classified as a Class 9 hazardous material. When shipping by air, packages must comply with IATA Packing Instruction 954, include the proper shipping name, UN number, net weight of dry ice and Class 9 hazard label. Packaging must allow CO₂ gas to escape—sealed plastic bags or metal containers are prohibited. The maximum allowable amount of dry ice per package in air transport is 200 kg. FedEx notes that plastic coolers must have openings to ensure ventilation and recommends using quality fiberboard, plastic or wooden boxes with polystyrene insulation.
In the United States, dry ice is not regulated for ground transport if packaged correctly, but packages must still be marked with the shipper and recipient’s names and addresses, the proper shipping name and UN number. Training in dangerous goods regulations is required for anyone preparing dry ice shipments.
Best Practices for Safe Handling
Wear protective gloves and goggles when handling dry ice to prevent frostbite and eye injury.
Allow ventilation: never place dry ice or dry ice packs inside sealed containers. Use insulated bags or boxes with vents.
Label clearly: mark packages with “Dry Ice” (or “Carbon Dioxide, Solid”), the UN 1845 number and the net weight.
Do not overfill: follow the 200 kg limit for air shipments and adjust the amount based on container size and duration.
Include instructions for crew: note in the airway bill that the package contains dry ice.
Dry Ice vs PCM vs Gel: Comparative Analysis
Dry ice isn’t the only refrigerant for cold chain shipments. Phase change materials (PCM) and gel packs offer alternatives. PCM packs absorb and release heat at predefined temperatures, typically between +2 °C and –20 °C, and are reusable and non hazardous. Gel packs freeze at 0 °C and provide chilled conditions. To help you choose, the following table compares typical hold time, reuse cycles, temperature range and practical benefits:
| Coolant Type | Typical Hold Time (h) | Reuse Cycles | Temperature Range | What It Means for You |
| Premium dry ice pack | 72–120 | 100–200 | –78.5 °C | Offers deep freeze integrity for multi day routes with lower total cost per shipment |
| Standard dry ice pack | 24–48 | 10–20 | –78.5 °C | Suitable for overnight or two day shipments but generates more waste |
| –21 °C PCM brick | 24–72 | 12–24 | –21 °C | Ideal for ice cream lanes or partial freeze shipments; easier handling |
| 0 °C gel pack | 24–48 | 10–20 | 0 °C | Best for chilled goods; not suitable for deep frozen items |
| Reusable PCM (2–8 °C) | 48–96 | 50–100 | +2 °C to –20 °C | Offers stable temperatures with minimal regulatory burdens and reduced CO₂ emissions |
Cost and Sustainability Considerations
Dry ice is inexpensive per shipment but must be replaced each time and contributes to CO₂ emissions. The U.S. Department of Transportation and IATA classify it as hazardous, requiring labeling and training. PCMs and gel packs have higher upfront costs but are reusable and non hazardous, simplifying compliance. Premium dry ice packs bridge the gap: they still use dry ice but integrate PCM matrices and smart insulation to reduce sublimation by up to 30 %, extend hold time and cut re icing touch points.
Real World Example: A frozen meal brand switched from four small gel packs to two high mass premium dry ice packs. The change cut packing time by about 25 % and maintained –20 °C for 48 hours during July’s hot lanes. The longer hold time and reduced labor improved efficiency and reduced waste.
Sizing and Handling Dry Ice Packs: Practical Tips
Right Sizing the Refrigerant
For medium sized insulated shippers (20–30 L), start with 5–7 lb (2.3–3.2 kg) of dry ice per 24 hours. Increase to 10–15 lb for 40–60 L boxes over 48 hours and 18–22 lb for 60–80 L boxes over 72 hours, adding insulation for hot routes. A simple formula from Tempk multiplies box volume by duration and applies multipliers for ambient conditions and insulation:
# Dry ice mass estimatordef estimate_dry_ice_mass(volume_liters, duration_hours, ambient=’moderate’, insulation=’good’):
“””Estimate dry ice mass (lb) based on volume, duration, ambient temperature and insulation.”””
base_mass = 0.25 * volume_liters * (duration_hours / 24) # baseline for moderate ambient & good insulation
ambient_multiplier = {‘cool’: 0.9, ‘moderate’: 1.0, ‘hot’: 1.35}[ambient]
insulation_multiplier = {‘good’: 1.0, ‘better’: 0.8, ‘best’: 0.65}[insulation]
return round(base_mass * ambient_multiplier * insulation_multiplier, 1)
# Example usage:
required_mass = estimate_dry_ice_mass(volume_liters=40, duration_hours=48, ambient=’hot’, insulation=’better’)print(f”Estimated dry ice mass: {required_mass} lb”)
Handling Tips
Pre chill products and liners to slow sublimation and maximize hold time.
Use spacers and airflow: leave space around the packs or surround the payload with dry ice to improve contact and airflow.
Layer insulation: combine foil or vapor barriers with expanded polystyrene (EPS) or vacuum insulated panels (VIPs) to boost thermal resistance.
Adjust mass for weather: double the dry ice mass for hot lanes; add a 25–50 % buffer and validate with a data logger.
Validate with data loggers: insert temperature and humidity data loggers to ensure the shipment stays within required ranges.
2025 Innovations and Trends in Cold Chain Logistics
IoT Enabled Monitoring and Predictive Analytics
Cold chain monitoring solutions now use sensors, data loggers, GPS trackers and cloud platforms to provide real time temperature and humidity data. These systems send alerts when deviations occur, allowing immediate corrective action and reducing waste. The market for cold chain monitoring was valued at USD 5.3 billion in 2022 and is expected to reach USD 10.2 billion by 2026, growing at a CAGR of 16.6 %. Grand View Research estimates the market at USD 35.03 billion in 2024 with a projected 23 % CAGR from 2025 to 2030, reflecting rapid adoption driven by regulations and IoT advances.
Blockchain for Traceability
Blockchain technology creates a tamper proof ledger of shipment events, ensuring end to end traceability. Real time logs of temperature, humidity and travel time can be shared with stakeholders to enhance trust and compliance. This is particularly valuable for pharmaceuticals, where data integrity and IP protection are critical.
Solar Powered Cold Storage
In regions with unreliable electricity, solar powered cold storage units provide sustainable solutions for temperature sensitive medicines. Solar installations can reduce energy costs—commercial solar rates range from 3.2 to 15.5 cents per kWh, compared with 13.10 cents from utility grids. This helps bridge energy gaps in rural areas and lowers operating costs.
Smart Sensors and AI Driven Route Optimisation
IoT sensors with GPS functionality monitor temperature and location in real time. When unsafe temperatures are detected, the system automatically alerts operators via text or app notifications. Integrating artificial intelligence allows route optimisation based on real time traffic and weather data, reducing transit times and the risk of temperature excursions. Predictive analytics identify potential failures before they occur, further enhancing reliability.
Portable Cryogenic Freezers
For biologics and cell therapies needing –80 °C to –150 °C, portable cryogenic freezers provide mobile ultra cold storage. These devices support last mile delivery of advanced therapies and represent an emerging segment of the cold chain equipment market.
Material and Design Innovation
Manufacturers are developing new absorbent materials and polymers that reduce dry ice loss by up to 30 %. Modular designs allow shippers to customise insulation thickness, lowering freight costs and emissions. Integrated IoT sensors and industry standards like IATA ONE Record and GS1 EPCIS 2.0 enable connected packaging that shares sensor data end to end.
FAQ (Frequently Asked Questions)
Q1: What’s the difference between a dry ice bag and a dry ice pack?
Dry ice bags are insulated containers designed to hold refrigerants and products, while dry ice packs are the cold source itself. Packs contain SAP and freeze to provide cold without water.
Q2: How long do dry ice packs last?
Standard dry ice packs maintain ultra cold temperatures for about 24–48 hours, whereas premium packs hold –78.5 °C for 72–120 hours and can be reused 100–200 times.
Q3: Are dry ice packs safe for food shipping?
Yes. Dry ice packs use non toxic SAP and water and remain encased inside sealed shells, so any leakage poses little risk. Ensure packages allow venting and follow labeling rules.
Q4: What are the regulations for shipping dry ice?
Dry ice is regulated as UN 1845, Class 9. Air shipments must follow IATA Packing Instruction 954, include hazard labels and allow CO₂ to escape.
Q5: How do I dispose of dry ice packs?
Allow the pack to thaw and sublimate in a well ventilated area away from people and pets. Once empty, many premium packs are reusable; if not, dispose of them according to local hazardous waste guidelines.
Summary and Recommendations
Dry ice bags and dry ice packs are indispensable tools for maintaining the integrity of temperature sensitive shipments. Dry ice packs made with SAP and non woven films provide flexible, moisture free cooling, while premium packs combine composite shells, PCM matrices and insulated liners for hold times up to 120 hours. Compared with gel packs and standard PCM bricks, premium dry ice packs offer superior cold retention and reusability. However, dry ice is hazardous and regulated; packages must vent CO₂, carry the UN 1845 label and follow IATA rules. Emerging technologies like IoT sensors, blockchain traceability and AI route optimisation will continue to improve cold chain visibility and efficiency. For a cost effective, sustainable cold chain, choose reusable premium dry ice packs, monitor shipments with smart sensors and stay current with regulatory updates.
Next Steps
Evaluate your shipping needs: Determine the temperature range, shipment duration and regulatory requirements for your products.
Choose the right refrigerant: Use premium dry ice packs for deep freeze shipments, PCM for medium temperatures, and gel packs for chilled goods.
Implement monitoring: Invest in IoT enabled data loggers and sensors to track temperature, humidity and location in real time.
Train your team: Ensure staff preparing dry ice shipments complete the required hazardous materials training.
Contact experts: Consult with cold chain specialists to customise insulation, packaging and routing strategies.
About Tempk
We are Tempk, specialists in reusable cold chain packaging. Our product line includes premium dry ice packs, gel packs, PCM bricks, insulated bags, and vacuum insulated panels. We focus on sustainability—our reusable dry ice packs maintain ultra low temperatures for up to 120 hours and withstand 100–200 reuse cycles. We integrate IoT sensors for real time monitoring and work closely with logistics partners to optimise routes and reduce carbon emissions. Whether you ship vaccines, gourmet meals or laboratory samples, we’re here to help you design compliant, cost effective and eco friendly cold chain solutions.
Call to action: Ready to upgrade your cold chain packaging? Reach out to Tempk’s experts for a custom consultation.
