When you need to ship frozen goods, “same day dry ice packs” are the hero of the cold chain. They deliver ultra cold temperatures of around 78.5 °C ( 109.3 °F) and sublimate without leaving water. The global dry ice market is projected to grow from USD 1.66 billion in 2025 to USD 2.73 billion by 2032, while the U.S. cold chain packaging market expects a CAGR of 15.6 % through 2030. As online grocery and pharmaceutical demand soars, understanding how to use dry ice packs correctly can save your business time, money and headaches.
Understand what same day dry ice packs are and why they matter – how they work, the temperatures they maintain and key benefits.
Compare dry ice packs to gel packs and phase change materials – decide which refrigerant suits your shipment’s temperature range and duration.
Use dry ice safely – learn the right amount of dry ice, packaging methods and handling precautions to protect people and products.
Explore market trends for 2025 and beyond – discover the latest innovations, sustainability efforts and industry growth data.
Find answers to common questions – a practical FAQ section helps you solve shipping challenges quickly.
What Are Same Day Dry Ice Packs, and Why Do They Matter?
Direct answer
Same day dry ice packs are pre shaped blocks or pellets of solid carbon dioxide manufactured daily and delivered quickly to maintain frozen temperatures during shipment. They are extremely cold (around 78.5 °C or 109.3 °F) and sublimate directly to gas, leaving no wet residue. Their ultra cold nature makes them ideal for keeping products like ice cream, frozen meats and vaccines frozen during transit.
Detailed explanation
Same day dry ice packs are produced on demand so they have maximum cooling power when you receive them. Unlike standard ice packs, dry ice is solid carbon dioxide that transforms directly into carbon dioxide gas as it warms. This sublimation process avoids liquid water that can damage packaging or thaw products. The extremely low temperature means dry ice can keep items well below freezing for hours or days, making it the preferred option for shipments that must stay frozen. Because dry ice is considered a hazardous material in many countries, reputable suppliers deliver it freshly made and packaged to meet same day shipping timelines, ensuring you get the maximum cooling capacity.
How do same day dry ice packs work?
Dry ice works by absorbing heat as it sublimates. When you place the packs around your goods, they pull heat out of the payload until the dry ice evaporates into carbon dioxide gas. This constant sublimation maintains a low temperature environment that slows spoilage and inhibits bacterial growth. For example, when used with sealed frozen foods, dry ice can lower and maintain temperatures so that ice cream, meats or biologics remain solid for up to 72 hours. Because dry ice is denser than air, the released carbon dioxide pushes away oxygen inside the container, reducing oxidation and spoilage.
| Comparison | Dry Ice Packs | Gel/Ice Packs | What it means for you |
| Temperature | Approximately 78.5 °C | Around 0 °C (32 °F) | Dry ice keeps products frozen; gel packs keep them chilled above 0 °C. |
| Residue | Sublimates to gas without leaving liquid | Melt into water that can saturate packaging | Dry ice avoids leaks; gel packs may wet packaging. |
| Best for | Frozen foods, vaccines, biologics | Chilled goods like chocolate, cosmetics | Choose dry ice for frozen goods and gel packs for non freezing items. |
| Regulations | Classified as hazardous; subject to IATA/DOT rules | No hazardous classification | You must handle dry ice with training and follow labeling guidelines. |
| User handling | Requires insulated gloves and ventilation | Safe to touch; no special equipment | Dry ice demands safety gear; gel packs are user friendly. |
Practical tips and advice
For frozen shipments under 48 hours: Pack dry ice equal to the payload weight. For overnight shipping, half the payload weight may suffice. For 72 hour frozen shipments, increase dry ice to 1.5 times the payload.
Seal items properly: Dry ice can alter the texture of unsealed foods; ensure products are well sealed to prevent carbon dioxide contact.
Vent your container: Because dry ice turns into gas, containers must allow gas to escape to avoid pressure build up.
Never use dry ice with items sensitive to freezing: Flowers, fresh seafood and some pharmaceuticals require cooling, not freezing. Use gel packs or phase change material (PCM) packs instead.
Example: A small ice cream business needs to ship a 5 lb box of pints to a customer. By placing 5 lbs of dry ice on top of the box (and none underneath), the shipment can remain frozen for 24–48 hours. If the business expects a 72 hour transit window, they should add approximately 10 lbs of dry ice. Properly sealing the ice cream prevents carbon dioxide from altering the taste and texture.
How to Use Same Day Dry Ice Packs Safely
Safe handling and regulatory rules
Dry ice is considered a hazardous material because it sublimates into carbon dioxide gas and can cause frostbite or asphyxiation in enclosed spaces. Regulations from the U.S. Department of Transportation (DOT) and the International Air Transport Association (IATA) limit shipments containing more than 5.5 pounds (2.5 kg) of dry ice. Always check your carrier’s rules and label packages accordingly.
Protect yourself. Use tongs or insulated gloves to handle dry ice, and avoid direct skin contact to prevent frostbite. When preparing shipments, work in a well ventilated area since sublimation releases carbon dioxide gas.
Vent the container. A dry ice shipment must include vents or loosely closed lids to allow gas release. Never place dry ice in airtight containers; pressure can build and cause container failure.
Label and document. For air shipments, attach a Class 9 hazardous materials label and state the weight of dry ice on the airway bill. For ground shipments, follow DOT labeling requirements. Non hazardous shipments under 5.5 lbs still need basic markings to indicate dry ice use.
Packaging guidelines and dosage
Choosing the right amount of dry ice depends on payload weight and transit time. The following guideline provides a starting point based on the IPC dry ice calculator chart:
| Payload weight | Dry ice (24–48 h) | Dry ice (48–72 h) | Practical meaning |
| 5 lbs | 5 lbs | 10 lbs | Use equal weight for 1–2 days; double for 2–3 days. |
| 10 lbs | 10 lbs | 15 lbs | Equal weight keeps goods frozen up to 48 h. |
| 20 lbs | 20 lbs | 30 lbs | Larger packages need more dry ice to overcome thermal mass. |
| 30 lbs | 20 lbs top + 10 lbs bottom | 30 lbs top + 15 lbs bottom | Split dry ice above and below to distribute cooling. |
| 50 lbs | 35 lbs top + 15 lbs bottom | 50 lbs top + 25 lbs bottom | Heavier loads require layering to maintain uniform temperature. |
How to pack effectively. Place dry ice on top of the products because cold air sinks. Avoid placing dry ice directly against delicate packaging; use cardboard or bubble wrap as a buffer. Insert additional insulation (e.g., foam panels or insulated liners) to slow heat transfer. Seal seams with tape to minimise warm air infiltration.
Combine refrigerants when needed. For shipments requiring extended frozen conditions, you can supplement dry ice with gel packs. Gel packs slow the sublimation rate and act as a thermal buffer, prolonging the lifespan of the dry ice and maintaining more stable temperatures.
Safety reminders
Keep out of reach of children and pets. Dry ice can cause injury if touched.
Never store in airtight containers. The pressure of CO₂ gas can cause explosions.
Vent during transport. Leave a small gap or use insulated containers designed for gas release.
Dispose properly. Let unused dry ice sublimate in a well ventilated area; never place it in sinks or drains.
Selecting the Right Refrigerant: Dry Ice vs Gel Packs vs Phase Change Materials
Cold chain refrigerant options
Cold chain shipments rely on various refrigerants, each designed for specific temperature ranges and transit durations. According to Mercury’s 2025 report on next gen cold chain packaging, phase change materials (PCMs) offer reusable, stable temperature packaging with fewer shipping restrictions. Dry ice provides ultra low temperatures for deep frozen shipments but requires hazardous materials compliance. Gel packs keep goods chilled above freezing and are ideal for products that must not freeze.
Temperature range comparison
| Refrigerant | Typical temperature range | Best use cases | Notes |
| Dry ice | Below –70 °C | Frozen biologics, CRISPR materials, plasma samples, ice cream | Ultra cold; single use; subject to hazardous regulations. |
| Phase change materials (PCM) | +2 °C to –20 °C | Vaccines, biologics, clinical trial kits | Reusable; maintain stable temperature ranges; require freeze cycles before use. |
| Gel packs | Approximately 0 °C to +8 °C | Chocolate, cosmetics, insulin, chilled foods | Water based; safe and non hazardous; may cause moisture. |
Cost and sustainability considerations
Dry ice is inexpensive per shipment but must be replenished for each use. It also contributes to CO₂ emissions and requires specialized handling. Phase change materials have a higher upfront cost but can be reused multiple times, reducing long term costs and waste. Gel packs are affordable and easy to use but provide only chilled temperatures and may not be suitable for ultra cold shipments. When choosing a refrigerant, consider the required temperature range, shipment duration, regulatory complexity and sustainability goals.
Decision framework
Determine target temperature. If your product needs to stay below –70 °C, dry ice is the only option. For 2–8 °C or –20 °C ranges, PCMs or gel packs may suffice.
Estimate transit time. For less than 72 hours, gel packs or PCMs might work. For longer or deep freeze shipments, use dry ice or combine refrigerants.
Check regulatory requirements. Dry ice shipments must comply with IATA and DOT rules; PCMs and gel packs generally avoid hazardous classification.
Assess sustainability and cost. Reusable PCM reduces waste and long term expenses. Dry ice has low upfront cost but higher recurring costs and carbon footprint.
Market Trends and Innovations for 2025
Growth of cold chain packaging and dry ice markets
The U.S. cold chain packaging market was valued at USD 7.97 billion in 2024 and is expected to grow at a 15.6 % compound annual growth rate through 2030. This growth is driven by increasing demand for processed and frozen foods, expanded e commerce grocery delivery, and strict temperature control requirements for vaccines and pharmaceuticals. Additionally, technological advancements in smart packaging enhance supply chain monitoring and efficiency.
The global cold chain packaging refrigerants market, which includes gel packs, foam bricks and dry ice alternatives, was valued at USD 1.57 billion in 2024 and is projected to reach USD 2.92 billion by 2032. Europe dominated this market with a 31.85 % share in 2024. Product innovation and sustainable solutions, such as biodegradable gel packs and recyclable insulation materials, continue to drive growth.
Meanwhile, the global dry ice market is forecast to grow from USD 1.66 billion in 2025 to USD 2.73 billion by 2032, at a CAGR of 7.4 %. Asia Pacific leads the market with a 32.47 % share in 2024, spurred by expanding cold chain logistics, food and beverage demand, and pharmaceutical transport needs.
Innovations and sustainability
Biodegradable insulation and refrigerants. Companies are developing eco friendly insulation materials and refrigerant packs made from plant based polymers. These reduce plastic waste and carbon footprints.
Smart packaging and data loggers. Integrated sensors and Internet of Things (IoT) devices monitor temperature and location, alerting shippers when a shipment deviates from the desired range. Smart packaging improves traceability and regulatory compliance.
Reusable PCM systems. Advances in phase change materials allow multiple freeze–thaw cycles, reducing the need for single use dry ice. Reusable systems lower total cost of ownership and help companies meet sustainability targets.
Hybrid refrigerant solutions. Combining dry ice with gel or PCM packs can extend cooling duration and provide more stable temperatures. Hybrid systems are becoming standard for long distance shipping or mixed payloads.
Sustainable dry ice production. Manufacturers are exploring carbon capture technology to source carbon dioxide from industrial emissions, reducing the carbon footprint of dry ice production. Although still emerging, this approach could align dry ice usage with net zero targets.
Market insights and consumer behavior
Consumer preferences are shifting toward convenience and online ordering, increasing demand for meal kits, frozen groceries and direct to consumer pharmaceuticals. The processed food segment is expected to grow at an 18 % CAGR through 2030. As consumers insist on freshness and safety, companies invest in cold chain packaging to maintain quality during transport. Regulatory scrutiny and the need for traceability drive adoption of advanced temperature monitoring and compliant packaging.
Frequently Asked Questions
Q1: How much dry ice do I need for a 24 hour shipment?
For overnight shipments, pack roughly half the weight of your product in dry ice. For example, a 10 lb payload needs about 5 lbs of dry ice to stay frozen for a day.
Q2: Can I ship dry ice with fresh seafood or flowers?
No. Dry ice keeps products at extremely low temperatures. Items sensitive to freezing—like live seafood, flowers or certain pharmaceuticals—can be damaged. Use gel packs or PCMs instead.
Q3: Are dry ice packs safe to handle?
Handle dry ice with insulated gloves or tongs to avoid frostbite. Work in a well ventilated area, and never place dry ice in an airtight container.
Q4: What is the difference between phase change materials and dry ice?
PCMs maintain stable temperatures within specific ranges (+2 °C to –20 °C) and are reusable, while dry ice provides temperatures below –70 °C but is single use and subject to hazardous material regulations.
Q5: Do I need special documentation to ship dry ice?
Yes. For shipments exceeding 5.5 lbs, you must comply with IATA or DOT regulations, label packages, and declare dry ice on shipping documents.
Q6: Why choose same day dry ice packs instead of standard ice?
Same day dry ice packs arrive fresh and maintain ultra cold temperatures without leaving residue. They keep frozen products solid for longer periods compared with water based ice.
Summary and Recommendations
Same day dry ice packs provide reliable, ultra cold temperatures to keep shipments frozen during transit. Dry ice sublimates to gas, leaving no wet mess and preventing water damage. For frozen goods like ice cream or vaccines, dry ice packs outperform gel packs, which maintain temperatures above freezing. To use dry ice safely, calculate the correct amount based on payload and duration, use insulated gloves, ventilate packages, and comply with hazardous materials regulations. When selecting refrigerants, evaluate temperature requirements, shipment duration, regulatory complexity and sustainability goals. Emerging innovations like PCMs, smart packaging and hybrid cooling systems offer reusable and eco friendly alternatives.
Actionable next steps
Assess your shipment needs. Identify whether your product must remain frozen, chilled or at a specific temperature range.
Choose a reputable supplier. Work with a provider that offers same day dry ice packs and understands shipping regulations. Confirm freshness and packaging quality.
Calculate dry ice volume. Use the weight to ice ratio guidelines to determine how much dry ice you need for the transit time.
Implement safety practices. Equip staff with insulated gloves and training to handle dry ice safely.
Monitor shipments. Incorporate temperature sensors or data loggers to verify compliance and identify any deviations.
About Tempk
Tempk is a specialist in cold chain packaging solutions, offering same day dry ice packs and eco friendly refrigerants for industries ranging from food and beverage to pharmaceuticals. Our products are made with precision to ensure consistent quality and thermal performance. We deliver fresh, made to order dry ice packs that maintain ultra low temperatures, and we provide reusable phase change materials for clients seeking sustainable alternatives. With a dedicated R&D team and a network of distribution centers, we support businesses across North America with reliable packaging, regulatory guidance and custom solutions.
Call to action: Ready to keep your shipments frozen and compliant? Contact Tempk today for expert advice and a customized refrigeration strategy.
