Extra Cold Dry Ice Pack Sheet: Mastering Ultra Cold Shipping in 2025
Introduction
Keeping frozen products rock solid during long journeys isn’t just nice to have—it’s essential for food safety, drug potency and customer satisfaction. An extra cold dry ice pack sheet offers deeper freezing capability than standard gel packs or phase change materials (PCM). This article explains what makes these sheets so special, when to use them, how to size and handle them safely, and how 2025 cold chain trends affect your choices. By the end, you’ll know how to protect your shipments, reduce waste and stay compliant.
Understand extra cold dry ice pack sheets: Learn how these flexible blankets of solid CO₂ deliver –78.5 °C, why they outperform gel packs, and what “extra cold” really means.
Size and apply them correctly: Follow step by step sizing guidelines, quick calculations and packing patterns that maximize hold time.
Handle dry ice safely and comply with regulations: Know about UN 1845 labeling, ventilation, PPE and disposal rules.
Compare against gel packs and PCM: Use side by side data to choose the right coolant for different lanes and products.
Stay ahead of 2025 trends: Explore market growth, sustainability, IoT monitoring and other innovations shaping frozen logistics.
What Is an Extra Cold Dry Ice Pack Sheet and Why Use It?
A flexible blanket of solid carbon dioxide – An extra cold dry ice pack sheet consists of multiple pockets filled with solid CO₂ captured inside a super absorbent polymer matrix. When hydrated and frozen, the sheet becomes rigid enough to wrap around irregular shapes while remaining thin enough to fit tight spaces. Dry ice sublimates directly from solid to gas at about –78.5 °C (–109.3 °F), so it leaves no water residue and maintains ultra low temperatures far longer than water based ice or gel packs.
Why “extra cold” matters – The term refers to the extreme temperature and cooling capacity rather than a brand. Dry ice delivers around 571 kJ of cooling energy per kilogram as it sublimates, providing a deep freeze “battery” that can recover from door open delays and hot depots. Gel packs operate near 0 °C to –5 °C and typically last only 6–12 hours, while PCM panels around –21 °C provide a medium level of cooling. For shipments that must stay below –20 °C for 48–96 hours—such as ice cream, vaccines or specialty chemicals—an extra cold dry ice pack sheet offers the necessary temperature headroom.
How Sublimation Delivers Ultra Low Temperatures
When dry ice sublimates, the endothermic reaction absorbs approximately 571 kJ of heat per kilogram. This energy draw effectively cools the surrounding environment. Because the sheet wraps around the cargo, it eliminates warm corners and dead air pockets. Dry ice pellets poured loosely can shift and create uneven cooling, but a sheet stays in place, reducing temperature gradients and minimizing handling hazards.
Key Advantages Over Gel Packs and PCM
| Cooling Source | Nominal Temperature | Cooling Energy | What It Means for You |
| Dry ice (CO₂) | –78.5 °C | ~571 kJ/kg | Deep freeze control; ideal for frozen goods; requires venting and UN 1845 labeling |
| Gel packs | 0 °C to –5 °C | Low | Suitable for chilled but not frozen shipments; risk of meltwater |
| PCM (–21 °C) | ≈ –21 °C | Medium | Stable frozen range; limited recovery from heat spikes compared with dry ice |
High cooling capacity – Dry ice delivers the most cooling energy per kilogram, so you can use less total mass compared with stacking gel bricks or PCM panels. This efficiency reduces shipping weight and cuts costs.
Longer hold time – Rapid freeze dry ice sheets maintain ultra cold temperatures for up to 72 hours, whereas gel packs last 6–12 hours and PCM panels 24–72 hours. If your lane spans multiple days or includes unpredictable dwell time, dry ice provides a greater safety margin.
No mess – Because dry ice sublimates directly to CO₂ gas, there’s no meltwater to damage packaging, labels or goods. This makes it ideal for shipping pharmaceuticals, biologics and delicate frozen foods.
Space efficient and flexible – Extra cold dry ice sheets conform to irregular shapes and maximize contact with the product, reducing unused space and promoting uniform cooling. They are also lighter than water based ice, which can lower freight costs.
Consistent cold – Uniform contact reduces temperature gradients, ensuring sensitive products stay within their required temperature range. For example, a biotech company wrapped mRNA vaccine vials with dry ice sheets and maintained –75 °C for 72 hours despite ambient temperatures of 25 °C; the vials arrived dry and uncontaminated.
Sizing Your Extra Cold Dry Ice Pack Sheet
Getting the right mass and thickness is critical. Too little dry ice leads to premature thawing, while too much wastes money and increases emissions. Below are practical guidelines.
Thickness and Duration
| Transit Duration | Recommended Sheet | Approximate Dry Ice Mass per kg of Product | Practical Meaning |
| Up to 24 hours | 12 mm sheet | 1 kg dry ice per 1 kg product | Ideal for overnight shipments; keeps goods below –20 °C for one day |
| 24–48 hours | 18 mm sheet or two 12 mm layers | 1–1.5 kg dry ice per kg product | Suitable for two day deliveries; layering provides redundant cooling |
| 48–72 hours | 24 mm sheet or three 12 mm sheets | 2 kg dry ice per kg product | Essential for long transits; maintains –75 °C for three days |
Quick Field Rule
For a standard 12–24 litre expanded polystyrene (EPS) cooler shipping frozen food, start with 2–4 kg of dry ice for a 24 hour hold. For 48–72 hours, plan 4–8 kg, and scale up for 96 hours. The exact mass depends on insulation (R value), box size, ambient peaks and how often the parcel is opened.
Step By Step Calculation
Estimate heat leak (Q̇) – Multiply the box’s U value by its surface area and the average temperature difference between ambient and target.
Multiply by time (Q = Q̇ × hours) – Convert to kilojoules.
Add product pull down – If the product isn’t pre frozen, include the energy to cool or freeze it.
Add 20–30 % buffer – Accounts for handoffs, re sorting and weekend holds.
Divide by 571 kJ/kg – The result is your first pass kilograms of dry ice.
Adjusting for Insulation
| Duration | EPS 1.5″ Wall | EPS 2.0″ Wall | What It Means |
| 24 hours | 2–3 kg | 1.5–2.5 kg | Start small and validate with two loggers |
| 48 hours | 4–6 kg | 3–5 kg | Add buffer if last mile is hot |
| 72 hours | 6–9 kg | 5–7 kg | Consider dual layer sheets for long lanes |
| 96 hours | 8–12 kg | 7–10 kg | Upgrade to VIP panels or hybrid PCM + dry ice for extended trips |
Pack Out Pattern
Place the extra cold dry ice pack above the payload—CO₂ gas sinks, washing cold air over the product. Use side runners if space allows, and add only a small bottom pad when necessary to avoid waste. Always leave vent paths; never seal the container gas tight.
Use corrugated cardboard or kraft paper as a barrier between the sheet and delicate products such as glass vials. For irregular shapes, wrap the sheet completely around the cargo to ensure uniform contact.
Real World Examples
Biotech shipping vaccines – A biotechnology company shipped mRNA vaccines using flexible dry ice sheets that wrapped each vial. The sheets maintained –75 °C for 72 hours and sublimated cleanly, so the vials arrived dry and uncontaminated.
Seafood export – A seafood exporter shipping frozen fish across continents used a 24 mm dry ice sheet with a 1:1 dry ice to product weight ratio. By using vacuum insulated panels (VIP) and wrapping the sheet around each fish, the exporter maintained –40 °C for 60 hours, preventing temperature spikes and condensation.
Safety and Regulatory Considerations
Dry ice is exceptionally cold and classified as a hazardous material, so proper handling is mandatory.
Personal Protective Equipment (PPE)
- Insulated gloves and goggles– Always wear insulated gloves and safety goggles to avoid frostbite and eye injuries. Touching dry ice with bare hands can cause severe burns.
- Tongs or scoops– Use tools instead of hands to handle dry ice blocks, especially when breaking sheets into smaller pieces.
Ventilation and Storage
- Ventilation– As dry ice sublimates, it releases CO₂ gas. Store and dispose of sheets in well ventilated areas to prevent gas build up.
- Never seal airtight– Never store dry ice in airtight containers or vehicle trunks. Pressure from sublimating gas can cause a container to rupture.
Regulatory Compliance
- UN 1845 labeling– Dry ice is classified as “Carbon dioxide, solid” under UN 1845. Packages must display the proper shipping name, UN number and net weight on the same side as the hazard label.
- Title 49 CFR and IATA rules– In the United States, shipments containing more than 5.5 lb (2.5 kg) of dry ice must comply with Title 49 CFR regulations. For air shipments, follow International Air Transport Association (IATA) dangerous goods regulations, including net mass limits and shipper’s declaration requirements.
- Recipient safety– If end users handle the parcel, label the package clearly to warn about dry ice and include an instruction card to avoid cold burns and provide disposal guidance.
Safe Disposal
Dispose of dry ice outdoors or in a well ventilated area. Do not pour remaining dry ice into sinks or sealed bins; it can freeze plumbing or cause pressure build up. Train receivers to allow the dry ice to sublimate completely in an open space before discarding the sheet.
Choosing Between Dry Ice, PCM and Gel Packs
Selecting the right coolant depends on lane duration, temperature requirements and handling capabilities.
Performance and Cost Trade Offs
| Option | Materials | Relative Cost | Handling Requirements | Best Use | What It Means |
| Extra cold dry ice pack | CO₂ in polymer sheet | Medium | Requires PPE, venting and UN 1845 labeling | Frozen shipments lasting 48–96 h | Highest protection; best for high value frozen goods or variable lanes |
| PCM (–21 °C) | Organic or inorganic PCMs | Medium–high | Simple handling | Frozen shipments, 24–72 h | Provides a stable plateau; good for moderate holds but limited recovery from heat spikes |
| Gel packs | Water based gel | Low | Simple handling | Chilled shipments, 12–48 h | Not suitable for deep freeze; risk of meltwater |
Hybrid Approach
A hybrid pack out combines –21 °C PCM panels around the sides with an extra cold dry ice pack on top. This setup reduces total dry ice mass while maintaining stability and protecting packaging from brittle fractures.
Environmental and Cost Optimization
Right sizing your dry ice pack prevents waste and lowers emissions. Upgrading insulation (e.g., using vacuum insulated panels or thicker EPS walls) can cut required dry ice mass by 20–40 %. A reverse logistics loop to recover shippers and polystyrene alternatives reduces landfill impact and overall cost.
Simple actions like upgrading to thicker walls before adding more dry ice, creating lane specific sizing standards, and including QR code setup cards so recipients handle and recycle components properly can deliver significant benefits.
Market Insights: Cold Chain Packaging Growth
The cold chain packaging sector is booming thanks to surging demand for temperature controlled logistics across food, pharma and chemical industries. Here are the key figures you need to know.
Market Size and Growth
The global cold chain packaging market is projected to reach USD 27.1 billion in 2025 and is expected to expand to USD 104.7 billion by 2035, translating to a compound annual growth rate (CAGR) of 15.8 %. This growth reflects increased consumption of vaccines, biologics, frozen foods and temperature sensitive chemicals around the world.
Growth Drivers
- Surging demand for temperature controlled packaging– Growth in global trade of perishable goods, vaccines and biologics has significantly increased demand for efficient cold chain packaging solutions. Strict regulatory requirements in pharmaceutical and food industries further necessitate advanced thermal packaging.
- Technological advancements– Smart packaging solutions with IoT enabled temperature monitoring are revolutionizing logistics for biological products, frozen foods and high value chemicals. Phase change materials with superior thermal stability and reusability are gaining traction and, in some cases, replacing traditional dry ice.
- E commerce & online grocery growth– The rise of online food and grocery delivery services has increased the demand for insulated shippers, gel packs and foam based packaging. Consumers’ preference for fresh and organic food drives the need for extended shelf life solutions.
- Sustainability pressures– Companies are shifting toward biodegradable, recyclable and reusable packaging materials to reduce carbon footprints. Regulatory mandates on plastic waste and CO₂ emissions are pushing innovations in bio based cold chain packaging.
Market Segmentation (2025)
| Segment | Market Share | Key Benefits |
| Pallet shippers | 26.3 % | Bulk transport solution for food, pharmaceuticals and chemicals |
| Insulated containers | 22.8 % | Ideal for high value shipments requiring controlled temperatures |
| Foam bricks & gel packs | 18.4 % | Common in last mile delivery for food and medical supplies |
| Protective packaging (foam sheets & wraps) | 16.9 % | Ensures shock resistance while maintaining cold temperature |
| Phase change cold storage products | 15.6 % | High thermal efficiency; replacing traditional coolants like dry ice |
Material Composition
| Material | Market Share | Application Areas |
| Polyethylene (PE, PP, PET) | 47.2 % | Lightweight, durable; used in insulated containers and pallet shippers |
| Expanded Polystyrene (EPS) | 23.4 % | High insulation; preferred for biological samples and pharmaceuticals |
| Paper & Cardboard | 16.3 % | Recyclable; growing demand in eco friendly food packaging |
| Metal based materials | 13.1 % | Used for high security, long duration shipping |
Packaging Format
Reusable packaging accounts for 54.8 % of the market, offering cost effective and sustainable solutions that reduce waste. Disposable packaging still holds 45.2 % share, mainly in export shipping and emergency logistics.
End Use Industries
The food and beverage sector dominates cold chain packaging with 38.2 % share, driven by rising demand for frozen, fresh and organic foods. Pharmaceuticals and healthcare follow at 29.7 %, reflecting growth in biopharmaceuticals, vaccines and medical shipments. Cosmetics and personal care contribute 14.6 %, and industrial chemicals and specialty materials account for 10.9 %.
Regional Growth and Trends
| Region | Projected CAGR (2025–2035) | Key Trends |
| North America | 14.3 % | Growth in biologics and personalized medicine fuels demand; the United States dominates due to stringent FDA regulations on cold chain logistics |
| Europe | 15.1 % | Strict environmental regulations drive demand for sustainable packaging; Germany and the UK invest in carbon neutral solutions |
| Asia Pacific | 16.4 % | Booming food exports and rapid expansion in biopharma logistics; e commerce grocery services fuel demand |
| Latin America | 13.7 % | Increasing investment in temperature controlled logistics |
| Middle East & Africa | 13.5 % | Growth in pharma cold storage and high end food imports |
Challenges and Market Constraints
- High costs– Temperature controlled packaging is more expensive than standard packaging, making affordability a challenge for small businesses.
- Strict regulations– Regulatory mandates require pharmaceutical and food companies to maintain strict temperature controls, with failure leading to product loss and financial penalties.
- Supply chain disruptions and energy consumption– Rising energy costs and logistical disruptions impact the efficiency of cold chain storage and transportation. Energy efficient and passive cooling solutions are being developed to mitigate these challenges.
2025 Trends in Extra Cold Dry Ice Pack Logistics
The cold chain industry is evolving rapidly, and extra cold dry ice pack programs are no exception. Several emerging trends are reshaping how companies design and execute frozen shipments.
Smarter Right Sizing and Data Driven Optimization
Modern warehouse management systems (WMS) embed estimators that select the correct dry ice mass based on lane and season. Companies combine data loggers with lane analytics to trim excess mass without risking thaw. For example, packaging suppliers now offer sizing calculators and dashboards that compare actual temperature curves with predicted performance. These tools help reduce waste and cut carbon emissions while protecting quality.
Safer Pack Outs and Simplified Standard Operating Procedures (SOPs)
Teams are simplifying instructions into one page SOPs with photos and tables that list net kilograms by lane. By training staff with hands on demos and checklists, they reduce handling errors and improve compliance. Tighter SOPs also speed induction at hubs and ensure consistent quality across shifts.
Lower Impact Materials and Sustainability
Packaging suppliers offer recycled content EPS and lighter VIP panels that maintain insulation while reducing volume. Hybrid pack outs using PCM sidewalls plus a top load dry ice layer reduce total CO₂ sublimation, lowering environmental impact. Companies also implement reverse logistics programs to collect and reuse shippers, reducing waste.
Technology Integration and Real Time Monitoring
The broader logistics industry continues to integrate AI, IoT and real time tracking to enhance efficiency, accuracy and transparency. In cold chain logistics, IoT sensors and predictive algorithms monitor temperature, humidity and door openings in real time, helping to prevent losses and ensure shipment integrity. Smart tags and blockchain records support full traceability from origin to delivery, meeting stricter global regulations.
Sustainability and Energy Efficiency
Logistics providers are investing in solar powered warehouses, electric refrigerated trucks and high efficiency cooling systems to reduce their carbon footprint. There is also a push toward eco friendly practices across the supply chain, such as optimizing routes to reduce fuel consumption and adopting biodegradable or recyclable packaging materials.
Climate Resilience and Collaborative Logistics
Climate change introduces greater risk of disruptions from floods, heatwaves or storms. Companies are building modular warehouses and distributed storage facilities to ensure continued operation during extreme events. Collaborative logistics—pooling frozen loads among multiple suppliers and leveraging shared platforms—helps reduce emissions and costs while improving network resilience.
Practical Tips for Using Extra Cold Dry Ice Pack Sheets
Specific Scenarios
Shipping ice cream – Use a top load extra cold dry ice pack to maintain a frozen core and buffer heat spikes. Pair with PCM sidewalls for longer durations and place a corrugated barrier between the sheet and cartons. Start with 4–6 kg of dry ice for a 48 hour lane and validate with a temperature logger.
Direct to consumer meal kits – Follow the field rule: 2–4 kg of dry ice for 24 hour holds. Top load placement and vented lids reduced summer failure rates from 6.8 % to 0.9 % for one meal kit brand. Include gloves and a simple disposal card for customers.
Biologic samples – For vaccines or biologics that must remain below –50 °C, choose dual layers of 18–24 mm sheets and pre condition containers. Use VIP panels and data loggers, and ensure UN 1845 labeling.
Specialty chemicals – Some chemicals must stay frozen but cannot contact CO₂. Use a barrier layer such as PCM panels on the bottom and sides, then place the dry ice pack on top separated by corrugated cardboard.
Interactive Self Test: Are You Pack Out Ready?
Use this scoring system (0 = no, 1 = partly, 2 = yes) to assess your preparation. Add up your points and see how ready you are.
Lane duration validated with a logger in the last 90 days.
Insulation upgraded or verified (2″ EPS or VIP for long lanes).
Extra cold dry ice pack top load with side runners and corrugate barrier.
Vented lid + UN 1845 label with net kg listed.
SOP card for receivers and gloves included.
Results:
8–10 points: You are pack out ready—ship with confidence.
5–7 points: Tweak the mass or insulation, run a test and adjust.
0–4 points: Pilot a trial shipment before going live.
Building a One Page SOP
An effective SOP ensures anyone on your team can assemble a dry ice pack safely in under five minutes. A suggested outline includes PPE, staging, box preparation, product loading, cold source placement, void fill, sealing and labeling, and handoff steps. Include a photo of the correct pack out and a table listing net kilograms by lane for quick reference.
Frequently Asked Questions
How much extra cold dry ice pack do I need for a 48 hour shipment?
Plan 4–6 kg of dry ice for a mid size EPS shipper, then validate with a temperature logger. Hot lanes or weekend holds may require additional buffer.
Is an extra cold dry ice pack safe for food shipments?
Yes, provided you allow ventilation and separate the dry ice from unpackaged food. Wrap or partition the sheet so it does not come into direct contact with edible items.
Can I fly with an extra cold dry ice pack?
Air shipments allow dry ice within net mass limits and with proper labeling. Check your carrier’s current dangerous goods regulations and mark the package “UN 1845” with net kilograms.
Dry ice vs –21 °C PCM—which is better?
For deep freeze lanes or heat spikes, choose the extra cold dry ice pack; for stable 24–48 hour frozen lanes, PCM can work well with less handling.
Where should I place the extra cold dry ice pack in the box?
On top. CO₂ gas sinks, so top loading washes cold air downward for better hold time.
What happens if the box is airtight?
Pressure can build as dry ice sublimates. Always provide a vent path and never seal containers gas tight.
Summary and Recommendations
An extra cold dry ice pack sheet delivers unmatched sub zero control for frozen shipments. Because dry ice sublimates at –78.5 °C, it absorbs heat efficiently and leaves no residue. Proper sizing—using field rules, quick calculations and test shipments—ensures the right mass for each lane. Top loading, venting and UN 1845 labeling are essential. Pairing dry ice with PCM panels and upgrading insulation can reduce mass and environmental impact. Data driven sizing, simplified SOPs and smart sensors are trends shaping 2025. Keep learning and adjust your pack outs as conditions and technology evolve.
Actionable Next Steps
Audit your frozen lanes – Use a logger to validate hold times and heat loads. Identify where extra cold dry ice packs can improve reliability.
Optimize insulation – Upgrade to thicker EPS or VIP panels before adding more dry ice. Consider hybrid PCM + dry ice solutions.
Develop a one page SOP – Create simple instructions and train staff. Include PPE requirements, pack out photos and lane specific tables.
Embrace data and technology – Integrate IoT sensors and analytics to right size your dry ice mass and reduce waste. Adopt sustainable materials and energy efficient equipment.
Consult a packaging engineer – For complex lanes or high value products, seek expert advice to design a compliant, cost effective solution.
About Tempk
We are a cold chain solutions team focused on practical packaging, validated pack outs and data driven optimization. Our products span EPS and VIP shippers, –21 °C PCM panels, and extra cold dry ice pack programs with SOPs, calculators and training. We help you reduce failures and cost through clear steps and real data.
Call to Action
Ready to optimize your frozen shipments? Contact us to schedule a lane audit and receive a tailored extra cold dry ice pack sizing sheet. Our packaging engineers can help you design compliant, efficient solutions that meet your unique needs.
