If you ship perishables or lifesaving medicines, you’ve likely wrestled with messy, toxic ice packs or rigid foam coolers. A biodegradable dry ice ice pack changes that narrative. This innovative refrigerant combines dry ice’s ultra cold performance with eco friendly materials that break down in landfills. New flexible sheets filled with solid carbon dioxide keep goods at –78.5 °C for up to 72 hours while biodegradable resin degrades 92 % in four years. In this guide you’ll learn how the technology works, why sustainability is now mandatory, and how to select and use these packs to meet 2025 regulations.
What makes a biodegradable dry ice ice pack sustainable? – discover how plant based films and degradable resins meet EPS bans and reduce landfill impact.
How do biodegradable dry ice ice packs compare to gel packs and phase change materials? – learn about temperature ranges, hazardous classifications and residue differences.
Which industries benefit the most? – explore use cases in food, pharmaceuticals and e commerce logistics.
How to size, handle and dispose of biodegradable dry ice ice packs? – step by step guidelines for safe preparation and sustainable disposal.
What are the latest 2025 trends? – see how IoT sensors, AI route optimization and global EPS bans are shaping cold chain packaging.
Why Should You Care?
Modern consumers are increasingly eco conscious: a recent market research report cited by Insulated Products Corporation found that nearly half of US consumers are very or extremely concerned about the environmental impact of packaging. At the same time, at least 12 US states and two territories enacted bans on expanded polystyrene (EPS) foam by May 2025. These bans target foam coolers, plates and even ice chests because EPS takes centuries to degrade and breaks into harmful microplastics. Switching to biodegradable dry ice ice packs and recyclable liners helps you comply with regulations, protect your brand and satisfy eco minded customers.
Below, we explore the science, applications and practical tips you need to start using biodegradable dry ice ice packs effectively.
What Makes a Biodegradable Dry Ice Ice Pack Sustainable?
Biodegradability and eco friendly materials – Unlike traditional foam coolers, which persist for centuries, modern biodegradable dry ice ice packs use a revolutionary grade of expandable polystyrene (EPS) resin that biodegrades 92 % over four years in wet landfill conditions. Microorganisms in biologically active landfills break down the resin at a molecular level without releasing harmful substances. This material offers the same thermal performance and cost as standard EPS but leaves almost no trace.
Plant based and recyclable films – The outer layer of a biodegradable dry ice ice pack is typically made of polyethylene or cellulose based film. Many manufacturers use non woven fabrics and permeable films that allow water vapor to escape while retaining structural integrity. For gel pack alternatives, companies like IPC have introduced drain friendly gel packs with recyclable plastic casings; the packs can be rinsed down the drain and recycled after use.
Dry ice encapsulation – Inside, the pack uses super absorbent polymer (SAP) cells filled with dry ice pellets or phase change materials. When you hydrate the cells and freeze them, they form a network of pockets that encapsulate CO₂. As the dry ice sublimates at –78.5 °C (–109 °F), it absorbs heat and turns directly into gas, leaving no moisture or residue. This sublimation process eliminates soggy packaging and cross contamination concerns common with water based gel packs.
Regulatory compliance and safety – Flexible dry ice sheets are classified as Class 9 hazardous materials and require UN 1845 labeling and special handling. Although the internal material is eco friendly, you must follow hazardous shipping protocols for dry ice. Most biodegradable dry ice ice packs are recyclable using standard polystyrene recycling methods and meet food contact guidelines.
Scientific Performance and Environmental Impact
Biodegradable dry ice ice packs provide ultra cold temperatures far beyond conventional gel packs. Flexible sheets can keep goods at –78.5 °C for up to 72 hours, whereas standard gel packs maintain 0–5 °C for 12–48 hours. Phase change materials (PCMs) occupy a middle ground, holding temperatures between –20 °C and –70 °C for 24–72 hours. The extreme cold capacity of dry ice makes it ideal for shipping mRNA vaccines and frozen seafood. Meanwhile, the biodegradable EPS used in some pack casings fully decomposes under anaerobic landfill conditions within a few years, unlike traditional foam that lingers for centuries.
Consumer sentiment is another environmental driver. With half of US consumers worried about packaging waste and a growing number of EPS bans across states, using biodegradable dry ice ice packs signals your commitment to sustainability.
How Does a Biodegradable Dry Ice Ice Pack Compare to Gel Packs and PCMs?
Biodegradable dry ice ice packs outperform gel packs and PCMs in temperature range and duration, but they come with special handling requirements. The table below summarises key differences.
| Cooling medium | Temperature range & duration | Practical considerations | Best use cases | Your benefit |
| Biodegradable dry ice ice pack | –78.5 °C to –20 °C; maintains ultra cold temperatures for 24–72 hours | Classified as a Class 9 hazardous material; requires UN 1845 labeling and vented containers to release CO₂ gas; sublimates directly to gas leaving no liquid residue | mRNA vaccines, biologics, specialty seafood; long distance frozen shipments | Ensures product integrity in extreme cold without moisture; reduces waste through biodegradable casing |
| Gel pack | 0 °C to 5 °C; moderate cooling for 12–48 hours | Non hazardous; easy to handle; melts into water requiring leak proof packaging; gel composed of water and sodium polyacrylate; not recyclable unless labeled drain safe | Fresh produce, meal kits, short haul shipments | Offers mild cooling at low cost; safe to handle but can add liquid weight and waste |
| Phase change material (PCM) pack | –20 °C to –70 °C; stable temperature band for 24–72 hours | Often non hazardous; PCMs absorb heat during phase transitions; no residue; heavier and costlier than gel packs | Biologics requiring strict 2–8 °C or –20 °C ranges; reusable shipments | Delivers precise temperature control without hazardous classification |
Expanded Comparison
Contact temperature and safety – Dry ice is extremely cold at –109 °F; contact can cause frostbite, so you need insulated gloves and vented containers. Gel packs, by contrast, have a surface temperature around 32 °F (0 °C) and can be handled briefly without gloves. PCMs occupy the middle ground depending on their formulation.
Residue and ventilation – Dry ice sublimates to CO₂ gas, which can build pressure in sealed containers and displace oxygen. Always use vented packaging. Gel packs release water as they thaw, increasing the risk of soggy packages and requiring leak proof film. PCMs generally leave no residue.
Regulatory classification – Dry ice is regulated as hazardous material and subject to airline quantity limits. Gel packs are usually unregulated but still require proper disposal. PCMs are often non hazardous.
Which Industries Benefit Most from Biodegradable Dry Ice Ice Packs?
Food Transportation
Fresh fruit, vegetables, meats and seafood require stable low temperatures to maintain quality. Dry ice packs retain flexibility after freezing and conform tightly to products, enhancing cooling efficiency. They are lightweight and space saving when unused, saving storage and transport costs. Because the materials are non toxic, leakage does not pollute the environment. Biodegradable casings further minimise waste.
Pharmaceutical & Biotech Logistics
Vaccines, biologics, blood samples and precision therapeutics demand strict temperature control. Flexible dry ice sheets keep goods frozen at –78.5 °C for up to 72 hours, making them ideal for mRNA vaccines or gene therapies that cannot tolerate warming. The biodegradable EPS casings allow pharmaceutical distributors to meet regulatory requirements while reducing landfill impact. High performance packaging ensures compliance with Good Distribution Practice and avoids costly product loss.
E commerce and Meal Delivery
Online grocers and meal kit services rely on cost effective, easy to use refrigerants. Dry ice packs are easy to use – simply soak, freeze and pack and remain somewhat flexible after freezing. In e commerce logistics, they enable short and long distance deliveries. Switching to biodegradable dry ice ice packs signals brand commitment to sustainability and reduces customer disposal headaches.
Choosing, Sizing and Applying Biodegradable Dry Ice Ice Packs
Direct Answer and Core Guidelines
Selecting the right size and thickness for a biodegradable dry ice ice pack is critical for temperature control. A rule of thumb is to match the weight of dry ice to the weight of the product (1:1 ratio). Choose sheet thickness based on transit time: 12 mm for up to 24 hours, 18 mm for ~48 hours and 24 mm for ~72 hours. Fully hydrate the polymer cells before freezing and pre chill the product and container to reduce thermal load.
Expanded Explanation
Flexible sheets come in various sizes. Sublimation occurs at the sheet’s surface, so insulating the sheet and lowering ambient temperature slows sublimation. When shipping a 5 kg box of frozen seafood for 48 hours, choose an 18 mm sheet and ensure 5 kg of dry ice in sheet form. Wrap the product completely or use a sandwich method – place sheets on top and bottom of the cargo. Vent the insulated container to allow CO₂ gas to escape while retaining cold air. Combine sheets with vacuum insulated panels or biodegradable EPS foam for improved thermal performance.
| Transit duration | Recommended sheet thickness | Approx. dry ice weight per kg of cargo | Benefit |
| ≤24 hours | 12 mm | 1 kg per kg of product | Lightweight sheet for overnight shipments; easy handling |
| 24–48 hours | 18 mm | 1 kg per kg | Balanced thickness for mid range transit; commonly used for food and medical samples |
| 48–72 hours | 24 mm or multiple 18 mm layers | 1–1.2 kg per kg | Provides long duration cold for long haul shipping or international shipments |
Practical Tips and Recommendations
Hydrate uniformly: Fully soak the pack for at least 15 minutes so polymer cells absorb water evenly. Uneven hydration causes brittle spots and uneven sublimation.
Pre chill everything: Chill the product, container and insulation before adding the dry ice pack to reduce initial heat load.
Vent and label: Use vented containers to release CO₂ gas. Apply hazard labels (UN 1845) to comply with shipping regulations.
Position strategically: Place packs on top and bottom or fully wrap around items to minimize temperature gradients.
Combine with smart sensors: Attach temperature data loggers or IoT sensors inside the shipment. Real time monitoring stops product damage by detecting temperature excursions early.
Use decision tools: Build a simple calculator on your website where users input product weight, required hold time and destination to generate recommended pack thickness and quantity.
Real world case: In one 2024 clinical shipment, a biotech company used flexible dry ice sheets to transport mRNA vaccines. By wrapping each vial with the sheet and venting the container, they maintained –75 °C for 72 hours despite outside temperatures of 25 °C. The vaccines arrived dry and uncontaminated because the sheets sublimated rather than melted.
Safe Handling, Disposal and Regulatory Compliance
Handling Safety
Dry ice packs are extremely cold. Always wear insulated gloves when handling them to prevent frostbite. Do not seal dry ice in airtight containers because sublimating CO₂ gas can create pressure and cause explosions. Airlines restrict the amount of dry ice allowed on board; consult carrier guidelines before shipping.
Disposal Guidelines
Although the casing is biodegradable, the gel in traditional ice packs is often composed of water and sodium polyacrylate. Most gel packs are not drain safe; they should be disposed of in the trash. According to a Baywise disposal fact sheet, gel ice packs labeled drain safe can be emptied down the drain following the instructions on the packet, but all other gel packs should be thrown away. Pouring non drain safe gel down the sink can clog pipes.
Drain friendly gel packs with recyclable casings offer a greener alternative. IPC’s 2023 update notes that drain friendly gel packs can be conveniently rinsed down the drain and recycled.
For dry ice, allow leftover CO₂ to sublimate in a well ventilated area away from children and pets. Do not flush dry ice into sewer systems. The biodegradable EPS casing can be recycled using polystyrene recycling programs where available.
Meeting 2025 Regulations
As more states outlaw EPS foam containers, biodegradable dry ice ice packs help you comply. At least 12 states and two US territories have banned expanded polystyrene (EPS) for food service by May 2025. Entry dates vary: Maryland (2020), Maine and Vermont (2021), New York (2022), New Jersey (2022), Colorado (Jan 1 2024), Washington (June 1 2024), Oregon and Rhode Island (Jan 1 2025), with California and Delaware phasing in throughout 2025. EPS takes centuries to degrade and releases toxic chemicals, prompting this legislation. Switching to biodegradable dry ice ice packs and recyclable liners demonstrates compliance and reduces legal risk.
Businesses shipping temperature sensitive goods should also understand hazardous materials classification. Flexible dry ice sheets are Class 9 and must be declared; carriers like FedEx and airlines limit the amount of dry ice per package. Consider combining dry ice with reusable PCM packs for shipments requiring moderate temperatures. PCMs often avoid hazardous classification and may reduce regulatory burdens.
Cost, Efficiency and User Benefits
Direct Answer
Many organizations worry that sustainable packaging costs more. However, biodegradable EPS has equivalent cost to standard EPS. Because you do not need to transport waste to a recycling facility, additional cost savings are realized. Flexible dry ice sheets are lightweight and compact when unused, reducing shipping expenses. The ability to avoid costly product loss by maintaining ultra cold temperatures for days yields a strong return on investment.
Expanded Explanation
Total cost of ownership includes procurement, shipping weight, labor and disposal fees. Biodegradable dry ice ice packs reduce disposal fees because they can degrade in landfills or be recycled. They also lower labor costs by eliminating messy gel cleanup and reduce shipping weight compared with bulky foam coolers. According to the Pelton Shepherd industry guide, gel packs for shipping are cost effective but offer moderate cooling and may require multiple packs. Dry ice packs deliver more cooling power per unit weight and can reduce the quantity needed.
User experience is improved because the packs do not leak water and can be disposed of responsibly. Consumers receive packages with a dry exterior, fewer ice crystals and a recyclable or biodegradable shell. With rising consumer concern for environmental impact, brands that use biodegradable dry ice ice packs build customer loyalty and differentiate themselves.
Practical Tips for Cost Management
Order in bulk to reduce unit cost; coordinate shipments across departments to leverage economies of scale.
Return programs: some suppliers offer returnable dry ice casings or exchange programs; incorporate them into your logistics.
Combine cooling mediums: for shipments requiring less extreme cold, supplement biodegradable dry ice packs with PCM packs to reduce hazardous material requirements and packaging costs.
Invest in training: ensure staff are trained on proper handling and sizing to avoid overpacking and waste.
Case Study: A meal kit company swapped EPS foam coolers for biodegradable EPS shippers and flexible dry ice sheets. Shipping weight dropped by 15 %, packaging waste decreased dramatically, and customer satisfaction scores improved because there was no messy gel to dispose of. The company also avoided new EPS compliance fees in states like New York and New Jersey.
2025 Latest Biodegradable Dry Ice Ice Pack Developments and Cold Chain Trends
Trend Overview
The cold chain sector is embracing technology and sustainability. According to a 2025 innovation report, smart sensors using IoT continuously monitor temperature and humidity. These sensors allow dynamic adjustments to environmental controls and provide real time visibility into temperature excursions, preventing product loss. AI powered route optimization software analyses traffic and cuts fuel usage by up to 15 %, reducing emissions. Cloud based platforms unify data from multiple sources, breaking down silos and improving decision making.
Energy efficient refrigeration technologies are gaining traction; magnetic refrigeration and solar powered cooling units reduce energy consumption and carbon footprints. Vacuum insulated panels (VIPs), now more affordable, provide high thermal resistance in thin profiles. Reusable and returnable cold chain systems are becoming mainstream, with rugged shells designed for multiple uses. These systems cut long term costs and waste.
From a materials perspective, recyclable fiberboard insulation, starch based liners and plant based biodegradable materials are replacing polystyrene. Biodegradable dry ice ice packs fit into this trend by offering both extreme cold and eco friendly casing. Coupled with IoT monitoring and AI logistics, they enable smarter, greener cold chains.
Latest Developments at a Glance
IoT enabled packaging: Real time temperature breach alerts and GPS tracking ensure cold chain integrity. Integrating sensors with biodegradable dry ice ice packs allows you to monitor the sublimation rate and temperature without opening the container.
AI driven route matching: Logistics software pairs shipments with optimal routes and weather forecasts, adjusting cooling mediums accordingly. This reduces energy use and improves on time delivery.
Vacuum insulated panels (VIPs): Thin, high performance insulation reduces package size and weight while maintaining cold. When combined with biodegradable dry ice packs, VIPs extend hold times.
Reusable returnable systems: Durable outer shells with RFID tracking enable closed loop shipping and reduce single use waste.
State and national legislation: Bans on EPS foam are expanding; the Farewell to Foam Act proposes nationwide bans by Jan 1 2026. These bans accelerate investment in biodegradable packaging.
Market Insights
Cold chain logistics is a booming industry. Global agricultural trade exceeds USD 1.1 trillion annually and the cold chain market is projected to reach USD 260 billion by 2024. Consumers and regulators are driving demand for eco friendly packaging, while companies face rising energy costs and supply chain complexity. Those adopting biodegradable dry ice ice packs, smart sensors and AI optimization will gain a competitive edge.
Frequently Asked Questions
Q1: Are biodegradable dry ice ice packs safe to use at home?
Yes, when used properly. Wear gloves to prevent cold burns and place the pack in a well ventilated container. Allow CO₂ gas to vent; never seal dry ice in an airtight box.
Q2: What is a biodegradable dry ice ice pack made of?
It combines a biodegradable EPS or plant based casing with super absorbent polymer cells filled with dry ice or phase change materials. The polymer absorbs water and creates pockets that encapsulate CO₂.
Q3: How do I dispose of a biodegradable dry ice ice pack?
Allow remaining dry ice to sublimate outdoors. If the pack’s gel is labeled drain safe, follow the instructions and rinse it down the drain; otherwise, dispose of the gel in the trash. Recycle or compost the casing where facilities exist.
Q4: Can I use biodegradable dry ice ice packs for short deliveries?
Yes. For shipments under 24 hours, choose a 12 mm sheet; it may even be more cost effective than multiple gel packs. However, gel packs might suffice for local deliveries that only require mild refrigeration.
Q5: What are drain friendly gel packs and how do they differ from biodegradable dry ice packs?
Drain friendly gel packs contain non toxic gel and a recyclable plastic casing. They can be rinsed down the drain and recycled. They provide moderate cooling, whereas biodegradable dry ice ice packs use dry ice and offer ultra cold temperatures. Use drain friendly packs when extreme cold isn’t required.
Q6: Are biodegradable dry ice ice packs more expensive?
No, the biodegradable resin costs roughly the same as standard EPS. You may even save money on waste disposal and shipping weight.
Q7: How do biodegradable dry ice ice packs support compliance with EPS bans?
They replace polystyrene coolers with biodegradable casings that degrade rapidly and meet recycling guidelines. With at least 12 states banning EPS foam foodware by 2025, these packs help you avoid penalties.
Summary and Recommendations
Key takeaways – Biodegradable dry ice ice packs deliver ultra cold temperatures up to –78.5 °C, keep goods frozen for up to 72 hours and leave no moisture residue because dry ice sublimates to gas. The biodegradable EPS casing breaks down 92 % in four years and costs roughly the same as standard EPS. With growing consumer concern and widespread EPS bans, switching to these packs is both environmentally responsible and commercially savvy.
Action plan – Start by auditing your current cold chain packaging and identify shipments that require ultra cold temperatures. For shipments under 72 hours requiring –20 °C or below, replace EPS coolers and gel packs with biodegradable dry ice ice packs. Use the sizing guide above to choose appropriate thicknesses and invest in temperature data loggers for real time monitoring. Train your team on safe handling and disposal. Finally, market your sustainability efforts to customers; highlight that your packaging complies with new EPS bans and reduces plastic waste.
About Tempk
Company background – Tempk is a leader in cold chain packaging solutions with an emphasis on sustainability and innovation. Our R&D center develops eco friendly, reusable and recyclable cold chain products ranging from biodegradable dry ice ice packs to insulated boxes and smart sensors. We bring decades of expertise in hot and cold therapy and cold chain logistics to ensure reliable temperature stability across industries.
Products and advantages – We manufacture flexible dry ice sheets that keep goods at –78.5 °C for up to 72 hours and use biodegradable EPS casings that degrade 92 % in four years. Our drain friendly gel packs feature recyclable plastic shells that can be rinsed down the drain. By integrating IoT monitoring and AI logistics, we help clients reduce waste, comply with regulations and enhance product safety.
Call to action – To explore how biodegradable dry ice ice packs can revolutionize your cold chain, contact our experts or request a sample. Together we can build a cooler, greener supply chain.
