Shipping perishable goods across the United States requires reliable temperature control without messy water leaks. A USA dry ice pack sheet offers long lasting cold without liquid residue, providing a flexible alternative to bulky blocks or gel packs. These sheets start as thin, paper like materials, absorb water to form ice and then freeze to deliver consistent –21 °C cooling for up to a day. In this guide you’ll learn why dry ice pack sheets are gaining popularity, how to size and use them safely, and what 2025 innovations are transforming cold chain logistics.
What a USA dry ice pack sheet is and how it works, including its layered construction and water absorption technology.
How to calculate the right quantity and arrangement of dry ice sheets for shipments of different weights and durations using the 1:1 rule and seasonal adjustments.
Safety and regulatory guidelines for shipping dry ice in the U.S., such as proper ventilation, labeling requirements and FDA/49 CFR regulations.
How reusable dry ice pack sheets compare to gel packs and PCM alternatives in terms of temperature range, leak risk, reusability and sustainability.
Emerging 2025 trends, from eco friendly insulation and IoT sensors to AI driven logistics, that will shape the cold chain industry.
What Is a USA Dry Ice Pack Sheet and How Does It Work?
A USA dry ice pack sheet is a flexible, reusable cooling pad that you soak, freeze, and cut to size to keep shipments frozen. Unlike rigid blocks of dry ice, these sheets begin as lightweight, foldable materials composed of small square cells. When soaked in water, the cells absorb moisture and swell into gel pockets; after freezing, they provide sustained, ultra cold temperatures down to –21 °C for up to 24 hours. Because the water is locked inside sealed cells, the sheet sublimates into carbon dioxide gas rather than melting into puddles, keeping your packages dry and clean.
Key Components: Outer Layer, Water Absorption Technology and Reusability
The typical dry ice pack sheet comprises three layers: an outer layer made from durable polyethylene or non woven fabric; an absorbent core containing super absorbent polymers that turn water into gel; and a cell structure that prevents leaks and allows the sheet to be cut to different sizes. When hydrated, the sheet transforms from a thin film into a pliable mat that conforms around goods. Its sealed cells stop gel leakage, enabling multiple freeze thaw cycles and reducing waste.
| Feature | Data/Description | Impact on Your Shipment |
| Prolonged cold retention | Maintains temperatures as low as –21 °C for up to 24 hours per sheet | Keeps frozen seafood, meat or biologics solid during overnight shipments without requiring refreezing. |
| No water residue | Sublimates into CO₂ gas without leaving liquid | Prevents soggy packaging and contamination of labels or products. |
| Reusability | Sheets can be rehydrated and refrozen multiple times, offering long term cost savings and reducing environmental waste | Lowers shipping costs and aligns with sustainability goals. |
| Flexibility | Sheets can be cut to fit various container sizes and wrapped around irregular shapes | Maximizes cooling contact and optimizes space within boxes or insulated bags. |
| Lightweight storage | Dry sheets are thin and lightweight, saving space before hydration | Reduces warehouse footprint and shipping costs, especially for bulk orders. |
How USA Dry Ice Pack Sheets Enhance Delivery Efficiency
Because dry ice sheets have no liquid water content, they eliminate the mess associated with melting ice. Traditional wet ice or gel packs melt and can soak through cardboard packaging, damaging labels and compromising product quality. Dry ice sheets sublimate to CO₂ gas, preserving the structural integrity of packaging. Additionally, they deliver consistent deep freeze temperatures, making them ideal for shipping frozen meats, seafood and pharmaceuticals across the country. For example, a Colorado seafood distributor used these sheets to ship salmon fillets to Florida during summer; by arranging the sheets around the product and insulating with foam, the fish arrived still frozen and free of condensation damage.
Practical Use Tips and a Real World Case
Hydrate thoroughly: Immerse the sheet in water for 10–15 minutes until each cell swells. Over soaking wastes water, while under soaking reduces cooling capacity.
Freeze completely: Lay the hydrated sheet flat in a freezer at –18 °C or below for at least 12 hours before use.
Cut and wrap: Use scissors to cut along cell lines to fit around products or line box walls. Ensure complete coverage for even cooling.
Layer correctly: Place the dry ice sheet on top of frozen products to allow cold air to sink and minimize temperature gradients. For longer transit times, line the sides and bottom with additional sheets (surround layout).
Reuse responsibly: After shipping, allow residual CO₂ to dissipate in a well ventilated area, then rinse and refreeze the sheet for the next shipment.
Case Example: A Midwest meal kit service started using dry ice pack sheets for cross country deliveries. By hydrating, cutting and layering sheets around vacuum sealed steaks and vegetables, they eliminated soggy boxes, reduced ice consumption by 30%, and improved customer satisfaction due to intact packaging on arrival.
How to Calculate the Right Quantity of Dry Ice Pack Sheets for Your Shipment?
Sizing your dry ice pack sheets correctly ensures products stay frozen without unnecessary weight or cost. A simple 1:1 ratio of dry ice weight to product weight provides a starting point for 48 hour shipments. For example, shipping 8 pounds of frozen meat would require roughly 8 pounds of dry ice sheets. However, adjustments are necessary based on seasonal temperatures, route complexity and insulation quality.
Sizing Formula and Seasonal Adjustments
Baseline calculation: Multiply product weight by 1.0 to estimate the starting dry ice sheet weight.
Seasonal factor: Add 35% extra during summer (0.35), 15% for spring/fall (0.15) and no addition for winter (0.00).
Route factor: Add 10% for multi hand off routes (0.10) or 15% for hot lanes (0.15). For direct routes, add zero.
Insulation factor: Subtract 10% when using premium insulation and 25% when using vacuum insulated panels.
Dry Ice Weight = Product Weight × (1 + Season + Route + Insulation).
| Product Weight | Starting Dry Ice (1:1) | Additions (Season/Route/Insulation) | What It Means for You |
| 4 lb | 4–5 lb | Add 35% in summer (1.4 – 1.75 lb) and 10% for multi hand off; subtract 10% with premium insulation | Ensures reliable 24–36 hour hold for small shipments. |
| 8 lb | 8–10 lb | Add up to 15% for hot lanes or multi hand off; subtract 25% with vacuum panels | Supports 36–60 hour shipments with improved insulation. |
| 12 lb | 12–15 lb | For extremely hot conditions, add up to 35%; premium insulation reduces dry ice weight by 20–25% | Maintains frozen conditions for 48 hours or more with proper packaging. |
Layout Strategies: Top, Surround and Hybrid
The arrangement of dry ice sheets affects sublimation rate and cooling duration. Top placement—placing sheets above the products—achieves sublimation rates of 8–12% per 24 hours and maintains temperatures for 24–36 hours. Surround layouts, where sheets line all sides of the product, reduce sublimation to 6–9% and extend cooling to 36–60 hours. Hybrid layouts (top and sides) offer the best of both worlds, with rates as low as 5–8% and durations of 48–72 hours. Choose the layout based on product sensitivity and transit time.
Leveraging Data and Technology
To optimize dry ice usage further, review historical shipping data and track temperature fluctuations across routes. AI driven logistics platforms analyse ambient temperatures and suggest the optimal dry ice quantity, saving costs and reducing waste. For example, real time temperature monitoring devices can alert you to deviations, allowing you to adjust future shipments accordingly. Partnering with cold chain experts or third party logistics providers ensures access to the latest best practices and technology.
What Safety and Regulatory Guidelines Apply to Shipping Dry Ice Pack Sheets in the USA?
Shipping dry ice in the United States is subject to strict regulations to protect handlers, carriers and recipients. The Food and Drug Administration (FDA) requires container closure systems to protect products from contamination. Additionally, the U.S. Department of Transportation’s 49 CFR part 173.196 and 173.199 specify packaging for diagnostic specimens and infectious substances, including triple packaging (primary receptacle, secondary container and outer packaging). Carriers such as UPS, FedEx and USPS impose limits on dry ice weight and require specific labeling. Understanding these rules is critical to avoid fines and ensure safety.
Ventilation and Container Guidelines
Dry ice sublimates into carbon dioxide gas, which can build pressure in sealed containers. Never seal dry ice in airtight or glass containers, as they may rupture or explode. Use ventilated expanded polystyrene (EPS) foam containers or vacuum insulated panels placed inside sturdy cardboard boxes to allow CO₂ to escape. Keep contents separate from the dry ice to prevent contact damage and maintain cold distribution. UPS suggests using 5–10 pounds of dry ice per 24 hours depending on insulation density, and to add extra dry ice to cover unexpected delays.
Labeling and Documentation Requirements
All dry ice shipments require clear labeling. The package must be marked “Carbon Dioxide, Solid, UN1845” and indicate the net weight of dry ice in kilograms. Airlines limit dry ice in passenger luggage to 2.5 kg (5.5 pounds). For air shipments, a 100 mm square Class 9 hazard label is mandatory when package capacity exceeds 30 kg. UPS and FedEx do not require a Dangerous Goods declaration if dry ice is the only hazardous material, but proper labels and documentation are still essential. Domestic shipments via USPS follow Packaging Instruction 9A; only domestic mail is allowed, and you must mark shipments with the contents being cooled and the net dry ice weight.
Carrier Specific Tips and Compliance Checklist
| Carrier/Regulation | Key Rules | What It Means for You |
| FDA 21 CFR 211.94 (b) | Containers must protect drugs from external factors that cause contamination | Use leak proof secondary packaging and insulated outer boxes for pharmaceuticals. |
| DOT 49 CFR 173.199/173.196 | Triple packaging required for diagnostic specimens | Place dry ice sheets outside the primary receptacle to ensure CO₂ can escape. |
| UPS | Use ventilated EPS containers; do not seal airtight; 5–10 lb per 24 h; add extra for delays | Always leave vents open and avoid over taping; calculate dry ice based on EPS density. |
| Airlines (IATA) | Label with UN1845, display net weight; 2.5 kg limit in passenger baggage | For larger shipments, work with cargo services and complete IATA paperwork. |
| USPS (Packaging Instruction 9A) | Domestic shipments only; label with contents being cooled and dry ice weight; Class 9 hazard label for air | Confirm route is domestic; abide by weight limit; include hazard label. |
Safety Checklist for Handling Dry Ice
Vent containers to allow gas escape; never place dry ice in a sealed glass or metal vessel.
Wear protective gear including insulated gloves and goggles to prevent frostbite and eye injuries.
Use sturdy insulation such as EPS foam or vacuum panels inside a cardboard box.
Label packages clearly with the UN 1845 designation and net weight of dry ice.
Document weight and add extra dry ice to cover potential delays.
Train staff on dry ice handling, CO₂ exposure hazards and emergency response procedures. Training is required for anyone in the supply chain who handles dry ice.
Real World Example: A diagnostic lab in New York shipped blood samples to California using dry ice pack sheets. They followed DOT’s triple packaging rule and labelled the box with the UN 1845 label and net dry ice weight. By leaving vents open and adding extra sheets for a possible customs delay, the samples arrived frozen and regulatory inspections were passed without issue.
Reusable Dry Ice Pack Sheets vs Gel Packs vs PCM Sheets: Which Is Better?
When considering cooling options, you may wonder how dry ice sheets stack up against traditional gel packs and newer phase change material (PCM) packs. Reusable dry ice sheets offer deeper cold than gel packs but require compliance with hazardous materials rules. PCMs provide reusable, controllable cooling within narrower temperature bands and often avoid hazardous labels.
Comparative Analysis
| Refrigerant | Temperature Range | Cooling Duration | Leak Risk | Reusability | Sustainability | Practical Implications |
| Traditional Gel Packs | 0 °C to 5 °C | Up to 6 hours | Moderate; gel can leak when punctured | Limited; often single use | Low; plastic waste generated | Good for refrigerated products like salads or beverages but unsuitable for freezing. |
| USA Dry Ice Pack Sheets | –21 °C for up to 24 hours | 24 – 72 hours depending on layout | Very low; sublimation leaves no liquid | Yes; rehydrated and refrozen multiple times | Moderate; single use CO₂ but reusable packaging | Ideal for frozen goods and overnight shipments; requires hazard labels and ventilation. |
| Phase Change Material (PCM) Sheets | –20 °C to 5 °C | 48 – 72 hours | Minimal; PCMs do not leak when sealed | Highly reusable; 500+ cycles | High; often biodegradable and recyclable | Suitable for refrigerated or mildly frozen goods; avoids hazardous labels and reduces carbon footprint. |
Why Choose Reusable Dry Ice Pack Sheets?
Reusable dry ice sheets merge the deep freeze capability of dry ice with the flexibility and sustainability of PCMs. They contain high density PCMs that maintain –20 °C to 5 °C, do not leak, and can be refrozen hundreds of times. They behave like smart thermostats for your shipment, adjusting to external temperatures and reducing temperature excursions by 25%. Businesses using reusable sheets have reduced waste by 60%, lowered packaging costs, and decreased customer complaints about temperature issues.
Tips for Selecting the Right Refrigerant
Identify your product’s temperature requirement: Use dry ice sheets for frozen goods (below –10 °C) and PCMs for refrigerated goods (2 °C–8 °C).
Consider shipping duration: For shipments under 24 hours, dry ice sheets may be sufficient; for 48–72 hour shipments, hybrid packouts or PCMs can reduce dry ice quantity and regulatory burdens.
Assess reuse and sustainability goals: If your business values circular economy practices, opt for reusable PCM sheets that last 500+ cycles.
Evaluate cost vs compliance: Dry ice requires hazard labels and training; PCMs avoid hazardous classifications and reduce documentation. Balance regulatory complexity against cooling needs.
2025 Trends and Innovations in USA Cold Chain Packaging
The cold chain industry is booming. Analysts project the global cold chain market to reach $500 billion by 2025, driven by growth in pharmaceuticals, biologics and online grocery demand. To meet increasing expectations, industry players are adopting smarter, greener technologies.
Key 2025 Innovations
Eco Friendly Insulation: Manufacturers are developing sustainable insulation materials that reduce environmental impact while enhancing thermal efficiency. These include bio based foams, recyclable vacuum panels and compostable linings.
Real Time Temperature Monitoring: IoT enabled sensors provide real time data on temperature, humidity and location, enabling rapid intervention to prevent spoilage. Some dry ice sheets incorporate RFID tags or smart labels to track temperature history.
AI Driven Logistics: Advanced algorithms analyse shipment data to predict sublimation rates and optimize dry ice quantities. AI platforms also manage routing to avoid delays and extreme conditions.
Hybrid Packouts: Combining dry ice sheets with PCMs or gel packs creates multi temperature zones within a single shipment. Hybrid layouts extend cooling duration to 72 hours and reduce sublimation rates.
Sustainability Metrics: Businesses are adopting life cycle assessments and carbon footprint tracking for packaging. Reusable sheets and PCMs can cut waste by up to 60% and lower emissions by 25%.
Market Insights
Demand for reliable cold chain solutions is surging across the U.S. Online meal delivery, grocery e commerce and biologic medicines all require consistent temperature control. Many businesses are shifting from single use gel packs to reusable dry ice sheets and PCMs to reduce environmental impact and compliance costs. Real time monitoring and AI analytics become baseline expectations for high value shipments. As carriers tighten regulations and consumers demand sustainability, adopting smart, eco friendly dry ice solutions will be essential for staying competitive.
Frequently Asked Questions
Q1: How long do USA dry ice pack sheets keep items frozen?
Depending on layout and insulation, a hydrated dry ice sheet maintains –21 °C for up to 24 hours. Surround or hybrid layouts can extend cooling to 36–72 hours. Use multiple sheets and premium insulation for extended durations.
Q2: Can I reuse dry ice pack sheets?
Yes. After the dry ice sublimates, simply vent the sheet outdoors, rehydrate it, and refreeze. Many sheets withstand multiple freeze thaw cycles, providing long term cost savings and reduced waste.
Q3: Do I need a Dangerous Goods declaration when shipping dry ice sheets?
For domestic non hazardous goods, you typically do not need a full declaration, but you must label packages with “Carbon Dioxide, Solid, UN1845” and list the net dry ice weight. International shipments or packages containing other hazardous materials may require a full declaration.
Q4: What should I do if a dry ice sheet comes into contact with food?
Avoid direct contact between dry ice and food. Always separate sheets from products using plastic liners or positioning them on top to ensure even cooling. Contact may cause extreme cold damage or frostbite.
Q5: How do I dispose of used dry ice sheets?
Allow leftover dry ice to sublimate in a well ventilated area away from people and pets. Rehydrate and refreeze the sheet if reusable; otherwise, dispose of it according to local recycling guidelines. Many sheets use recyclable plastics.
Q6: Are reusable PCM sheets a better option?
Reusable PCM sheets maintain temperatures between –20 °C and 5 °C and can be refrozen over 500 times. They don’t require hazardous labels and reduce waste by 60%, making them suitable for refrigerated or moderately frozen goods. However, they may not achieve the ultra cold temperatures of dry ice sheets.
Summary and Recommendations
USA dry ice pack sheets provide a versatile, leak free solution for shipping frozen goods across the country. Their water absorbent cells deliver ultra cold temperatures down to –21 °C for up to a day, while sublimation prevents messy residue. By following the 1:1 sizing formula and adjusting for season, route and insulation, you can tailor the quantity of dry ice sheets to your shipment and extend cooling to 72 hours. Observing regulatory guidelines—ventilation, labeling and proper packaging—ensures compliance with FDA, DOT and carrier rules. Reusable dry ice sheets and PCMs offer sustainable alternatives that reduce waste and costs. Embracing new trends such as eco friendly insulation, IoT monitoring and AI planning will help your business thrive in the rapidly expanding cold chain market.
Actionable Advice
Assess your product’s temperature needs: For deep freeze shipments, use dry ice sheets; for refrigerated goods, consider PCM alternatives.
Apply the sizing formula: Start with a 1:1 ratio of dry ice to product weight and adjust for season, route and insulation.
Select the right layout: Use top placement for short trips, surround layouts for extended durations, and hybrid packouts for maximum hold.
Follow regulations: Vent containers, label packages with UN 1845 and net weight, and comply with 49 CFR and carrier specific guidelines.
Explore reusable options: Invest in reusable PCM sheets or hybrid packouts to reduce waste by 60% and improve sustainability.
Leverage technology: Utilize IoT sensors and AI logistics platforms to monitor temperature and optimize dry ice usage.
Consult experts: Partner with cold chain specialists and carriers experienced with dry ice shipments to ensure compliance and efficiency.
About Tempk
At Tempk, we specialize in providing advanced cold chain solutions for the U.S. market. Our USA dry ice pack sheets, reusable PCM products and insulated containers are engineered to meet strict FDA and DOT regulations while maximizing cooling performance. We focus on sustainability by offering recyclable materials and reusable products that reduce waste and costs. Let our experienced team help you design the optimal cold chain system—from sizing formulas and layout strategies to real time monitoring and regulatory compliance. Contact us today for a tailored consultation and bring reliability and efficiency to your temperature sensitive shipments.
