Reusable gel dry ice pack sheets combine the ultra cold performance of dry ice with the convenience of gel packs, offering a flexible refrigerant that you can hydrate, freeze and reuse. These quilted sheets contain super absorbent polymer cells that swell when soaked in water and freeze to deliver temperatures as low as –190 °F. In this comprehensive guide you’ll discover how they work, why they outperform traditional dry ice or gel packs, how to size and use them safely, and what market and sustainability trends in 2025 mean for your cold chain logistics.
What is a reusable gel dry ice pack sheet and how does it work? – Understand the materials, hydration process and why the technology is different from standard gel packs.
When should you choose a gel dry ice pack sheet over conventional dry ice or gel packs? – Learn the advantages, limitations and cost factors of each option.
How do you hydrate, freeze and size these sheets effectively? – Follow step by step instructions and sizing guidelines for various shipment durations.
What are the benefits across different industries? – Explore applications for food, pharmaceuticals, biologics, electronics and subscription services.
What market and sustainability trends are shaping gel ice packs in 2025? – See how reusable packs are dominating the market, and discover new eco friendly innovations.
What Is a Reusable Gel Dry Ice Pack Sheet and How Does It Work?
A reusable gel dry ice pack sheet is a flexible blanket of quilted cells filled with a super absorbent polymer that can be hydrated and then frozen to deliver dry ice level cooling. Unlike solid blocks of dry ice, these sheets consist of many small pockets separated by seams; when you immerse the sheet in water, the polymer powder swells into a gel and becomes trapped in each cell. One side of the sheet is made from permeable fabric to allow water to enter, while the other side uses a durable plastic layer to prevent leaks. The hydrated sheet is pliable and can be cut or wrapped around irregular products. When frozen, the cells act like mini dry ice compartments, achieving extreme temperatures (Techni Ice sheets can be frozen down to –190 °F).
The combination of flexibility, powerful cooling and reusability distinguishes these sheets from standard gel packs. Hydrated sheets are cheaper to ship because they are flat and lightweight before hydration, yet they deliver uniform cold around every surface when frozen. The gel cells also provide extra insulation, trapping cold air next to the product and reducing thermal hotspots.
Understanding Materials and Construction
Reusable gel dry ice pack sheets rely on non toxic polymers and multi layer films. The gel typically consists of water absorbing polymers such as sodium polyacrylate or silica gel. Some manufacturers use cross linked polyacrylate polyalcohol copolymers combined with proprietary refrigerants for enhanced cooling. The sheet’s outer structure comprises two inner layers of high strength spun bonded fabric for durability and two outer layers of printed PET/LDPE laminate for printability and heat sealability. One way micro perforations allow water to enter during hydration while preventing leaks. Most products are food safe and produced under ISO 9001 and FDA approvals.
Hydration and Freezing Process
To activate the refrigerant:
Hydrate the sheet – Immerse the dry sheet in warm water for 5–15 minutes until air bubbles stop; the polymer cells will swell as the water absorbs. Hydrate through the permeable side and massage gently to ensure even swelling.
Freeze flat – Lay the hydrated sheet flat in a freezer. In a domestic freezer, these sheets can reach –0.4 °F to –5.8 °F; in blast freezers they can drop to –190 °F. Freezing flat ensures even cold distribution.
Cut and wrap – After freezing, cut along the seams to fit your container. The quilted structure keeps gel cells evenly distributed and allows the sheet to wrap tightly around products, maximizing surface contact.
Reuse and maintenance – After use, thaw the sheet, wipe dry and refreeze. Inspect for punctures before reuse and discard any damaged cells.
Comparing Cell Sizes and Hydrated Weights
| Product | Dry cell size / configuration | Hydrated weight | Practical benefit |
| Thermapack #337 Dry Gel Sheet | 3 × 3.7 in; 6 cells per row | ~37 lb when hydrated from a 33 ft sheet | Smaller cells provide flexible coverage for delicate items such as pharmaceuticals and chocolates. |
| Thermapack #637 Dry Gel Sheet | 6 × 3.7 in; 3 cells per row | ~49–50 lb from a 33 ft sheet | Larger cells last longer in extreme conditions, ideal for frozen meat or ice cream. |
| Techni Ice HDR sheet | 24 individually sealed pockets | Expands uniformly when hydrated | Provides flexibility and uniform cooling for custom containers. |
Practical Tips and Advice
Hydrate thoroughly – Use warm water and wait until bubbles stop; incomplete hydration leaves dry pockets that reduce cooling.
Pre chill your cargo – Refrigerate or freeze products and shipping containers before inserting the sheet to reduce thermal load.
Wrap tightly – Place the sheet above and below goods or wrap around each item; this maximizes contact and uniform cooling.
Inspect for punctures – Do not reuse sheets with damaged cells; leaks reduce performance and could contaminate products.
Case study: A specialty cheese producer switched from loose gel packs to 3 oz gel sheet dry ice pack sheets for summer shipments. After hydrating and freezing the sheets overnight, the team cut them to wrap each wheel. The result: consistent 2–8 °C temperatures during transit, a 20 % reduction in refrigerant weight and fewer temperature fluctuations reported by customers.
Why Choose Reusable Gel Dry Ice Pack Sheets Over Conventional Dry Ice or Gel Packs?
Reusable gel dry ice pack sheets bridge the gap between dry ice and standard gel packs. Dry ice sublimates at –78.5 °C (–109.3 °F), delivering intense cold but classified as a hazardous material and requiring special labeling and ventilation. Gel packs maintain temperatures around 2–8 °C and are safer to handle but may not keep goods frozen for long. Gel dry ice sheets provide extreme cooling like dry ice yet remain flexible, cuttable and easier to transport because they are not regulated as hazardous materials.
Advantages Over Gel Packs
Greater cooling capacity – Hydrated gel dry ice sheets can freeze to extremely low temperatures, keeping goods well below freezing for days, whereas gel packs freeze at 0 °C and melt into liquid.
Uniform coverage – The sheet conforms to irregular shapes and reduces dead air space, ensuring even cooling. Traditional gel packs leave gaps and can create hot spots.
Reduced leakage – Gel packs melt into water, risking leakage; dry ice sheets sublimate to CO₂ gas, leaving no liquid residue.
Reusability – Gel dry ice sheets can be thawed and refrozen multiple times, offering better cost efficiency for frequent shipments.
Advantages Over Traditional Dry Ice
Safer handling – Dry ice can cause frostbite and suffocation; it is a Class 9 hazardous material and requires hazard labels and weight limits. Gel dry ice sheets achieve similar temperatures but are not regulated as hazardous, making them easier to ship.
Less over cooling – Dry ice may overfreeze goods that should remain chilled. Hydrated sheets can maintain both ultra cold and chilled ranges, providing flexibility.
Flat shipping and storage – Gel dry ice sheets ship flat, saving space and shipping costs. Dry ice is bulky and sublimates quickly, requiring additional quantity for long durations.
Lower environmental impact – Unlike dry ice, which releases CO₂ during sublimation, reusable gel sheets can be reused and produce no greenhouse gas emissions during use.
Cost, Longevity and Temperature Differences
| Factor | Dry Ice | Gel Pack | Reusable Gel Dry Ice Sheet |
| Cost | Higher upfront cost; perishable; must be purchased regularly | Inexpensive and reusable; available in bulk | Moderate cost per sheet but reusable; lower shipping cost when dehydrated |
| Cooling duration | Long; sublimation rate ~10 lb per 24 hours in an insulated container | Stays cold up to six hours; warms quickly | Maintains ultra cold temperatures for 24–72 hours depending on thickness |
| Temperature range | –78.5 °C; ideal for frozen goods | 2–8 °C; ideal for chilled goods | –78.5 °C to –20 °C; flexible to achieve chilled or frozen states |
| Safety & regulations | Hazardous; requires UN 1845 label and weight limits | Non hazardous; simple disposal | Non hazardous; easier to transport and handle |
| Environmental impact | Sublimates to CO₂ gas; no plastic waste | Plastic waste and non recyclable materials | Reusable; some biodegradable options reduce waste |
Decision Tips for Specific Scenarios
Frozen shipments (>24 hours): Use gel dry ice sheets or dry ice for products that must remain below –20 °C. Dry ice offers the longest duration but requires hazardous handling; gel dry ice sheets provide flexibility and reduce regulatory burden.
Chilled shipments (2–8 °C): Choose gel packs or hydrated gel dry ice sheets without freezing. They maintain safe temperatures for dairy, chocolates and pharmaceuticals.
Mixed shipments: Combine dry ice with gel dry ice sheets to slow sublimation and maintain both frozen and chilled items in the same package.
Subscription services and returns: Reusable sheets and gel packs make sense when you can collect and refreeze them. Return logistics and cleaning should be factored into your cost analysis.
How to Use Reusable Gel Dry Ice Pack Sheets Safely and Effectively
Proper use maximizes cooling performance and ensures safety. Following a step by step process allows you to leverage the flexibility of gel dry ice sheets while complying with regulations.
Sizing and Application Guidelines
Sizing is based on the duration of transit and the thermal mass of your product. The rule of thumb is to match the weight of frozen refrigerant to the weight of your cargo (1 kg of sheet per 1 kg of product) and adjust sheet thickness according to the time needed.
| Transit duration | Recommended sheet thickness | Approximate dry ice weight per kg of product | Practical significance |
| Up to 24 hours | 12 mm flexible gel dry ice sheet | 1 kg per kg of product | Suitable for overnight or next day shipments; keeps cargo below –20 °C for one day. |
| 24–48 hours | 18 mm sheet or two 12 mm layers | 1–1.5 kg per kg of product | Ideal for two day deliveries and international flights. Layering adds redundancy and prolongs cold. |
| 48–72 hours | 24 mm sheet or three 12 mm sheets | 2 kg per kg of product | Enables extended transit for vaccines and cell therapies; multiple layers maintain –75 °C for three days. |
Application Tips for Specific Use Cases
Laboratory samples: Wrap each specimen bag individually with a sheet and place absorbent pads underneath to capture condensation.
Meal kit services: Pre freeze food items, then wrap them with an 18 mm sheet and add additional sheets on top; the sheet conforms to irregular shapes like whole fish or stacked steaks.
Pharmaceutical distribution: Use a 24 mm sheet for high value biologics; employ real time temperature sensors to monitor conditions.
Electronics and precision instruments: Combine gel dry ice sheets with desiccants to control humidity and protect sensitive electronics during transit.
Safety and Regulatory Considerations
Even though gel dry ice sheets are generally safer than dry ice, you still need to observe good practices:
Ventilation: Dry ice or gel dry ice sheets that incorporate dry ice release CO₂ gas; always use vented insulated containers or boxes with pressure relief valves to avoid gas buildup.
Labeling: For sheets that incorporate dry ice, comply with Class 9 hazardous labels and UN 1845 markings, including the net weight of dry ice. Weight limits typically cap at 200 kg per package.
Handling: Use insulated gloves, tongs and eye protection when handling sheets that are extremely cold. Avoid direct skin contact to prevent frostbite.
Disposal: Thaw the sheet completely before disposal. The gel is non toxic but should not be flushed down drains; small amounts can be sealed in a bag and placed in the trash. For biodegradable versions, compost the gel or incorporate it into garden soil following manufacturer guidelines.
Benefits and Applications Across Industries
Reusable gel dry ice pack sheets are versatile and serve multiple industries. The table and discussion below illustrate where they shine.
Industry Specific Applications
| Industry | Temperature requirement | Recommended cold pack | Practical significance |
| Food & meal kits | 0–8 °C for produce, dairy and prepared meals | Gel dry ice sheets (unfrozen or lightly frozen) or standard gel packs | Maintain freshness without freezing; reduce spoilage and condensation. |
| Frozen foods & ice cream | Below –20 °C | Gel dry ice sheets or dry ice | Keep frozen goods solid without over cooling; flexible sheets minimize freezer burn. |
| Pharmaceuticals and vaccines | Strict 2–8 °C or –20 °C to –70 °C | Gel dry ice sheets or phase change materials (PCMs) | Ensure regulatory compliance and maintain narrow temperature bands; reusable sheets lower waste. |
| Biologics & mRNA vaccines | –75 °C for 24–72 hours | Flexible dry ice sheets | Provide ultra cold conditions without moisture; essential for cell therapy and mRNA vaccines. |
| Electronics & specialty goods | 5–15 °C or 15–25 °C | Gel dry ice sheets combined with desiccants | Protect electronics from thermal stress and humidity; flexible sheets fit irregular shapes. |
| Subscription services | 0–8 °C for meal boxes | Reusable gel packs or gel dry ice sheets | Lower long term costs and reduce waste; return logistics needed for reuse. |
Practical Advice for Key Industries
Meal kit delivery: Pre chill ingredients and use 12 mm or 18 mm sheets depending on shipping duration. Place hydration instructions and disposal tips in the box to educate customers on reuse.
Pharma and biologics: Pair 24 mm sheets with temperature data loggers to comply with GDP/USP guidelines. Use double sealed bags to prevent contamination.
Seafood and meat exporters: Wrap each item with a gel dry ice sheet to reduce freezer burn and maintain uniform freezing. Comply with international dry ice weight limits.
Artisanal and dairy goods: Use lightly frozen sheets to maintain 2–8 °C and avoid freezing delicate textures; wrap goods individually and use absorbent pads.
Market Trends and Sustainability in 2025
Market Growth and Dominance of Reusable Packs
The global gel ice pack market is booming. Coherent Market Insights reports that the market will be valued at USD 311.2 million in 2025 and is expected to reach USD 572.5 million by 2032, with a compound annual growth rate (CAGR) of 9.1 %. Reusable packs are projected to dominate the market, holding a 55.6 % share in 2025. Non toxic gel packs are anticipated to represent 56.8 % of the materials market. North America is expected to lead with a 36.3 % share, while Asia Pacific will be the fastest growing region. These numbers reflect rising demand for eco friendly, reusable solutions across healthcare, sports therapy, and food logistics.
The surge is driven by several factors: increasing chronic pain prevalence (over 1.7 billion people suffer from musculoskeletal conditions) has led to higher adoption of reusable medical gel packs; and the expansion of biologics and vaccines during the COVID 19 pandemic highlighted the need for reliable gel packs equipped with IoT temperature loggers. In addition, Technavio predicts that the global reusable icepacks market will grow by USD 374.7 million from 2025–2029 at a CAGR of 5.5 %.
Sustainability and Eco Friendly Innovations
Consumer demand for environmentally responsible packaging is reshaping the cold chain industry. A Cryopak white paper notes that over 70 % of consumers favour environmentally friendly products, prompting manufacturers to invest in eco conscious refrigerants. Cryopak’s Eco Gel™ is made from a proprietary blend of natural, biodegradable materials and is both biodegradable and recyclable. The gel maintains consistent temperature control across multiple uses and meets FDA requirements for food and pharmaceutical contact. Pelton Shepherd’s Terra Ice gel pack, certified ASTM D6400, is fully compostable. These innovations demonstrate a move toward compostable and drain friendly gels that break down harmlessly and reduce landfill waste.
Sustainable packaging extends beyond the refrigerant: manufacturers are developing paper based gel pack pouches, compostable films and reusable insulating liners to lower carbon footprints. Some gel dry ice sheets incorporate plant based polymers and natural refrigerants to minimise environmental impact. Additionally, hybrid systems combining gel dry ice sheets with PCM panels enable precise temperature control with less dry ice consumption.
Latest Progress at a Glance
Biodegradable gels: Eco Gel™ and Terra Ice demonstrate that natural materials can match the performance of synthetic gels while reducing environmental impact.
IoT temperature logging: Pharmaceutical companies require gel packs equipped with sensors and IoT loggers to monitor transit conditions, improving compliance and quality control.
Hybrid PCM dry ice systems: Flexible dry ice sheets combined with phase change materials offer extended durations and precise temperature bands.
Regulatory clarity: Updated IATA and DOT guidelines clarify weight limits and labeling for dry ice and hybrid sheets, making compliance easier.
Consumer education: Companies now provide end user instructions for hydration, freezing, refreezing and disposal to maximise reuse and minimise waste.
Market Insights
Market data indicate strong momentum for reusable and eco friendly gel packs. North America’s dominance stems from advanced healthcare logistics and subscription meal services, while Asia Pacific growth is fueled by e commerce and food delivery. Demand for non toxic, plant based gels is increasing, driven by both consumer preferences and tightening environmental regulations. Manufacturers that invest in R&D for sustainable materials and IoT integration stand to gain a competitive advantage.
Frequently Asked Questions
How do you hydrate and freeze a reusable gel dry ice pack sheet? Immerse the dry sheet in warm water for 5–15 minutes until the cells swell and air bubbles stop. Gently massage to ensure even hydration. Then lay the sheet flat in a freezer to achieve temperatures as low as –5 °F in domestic freezers or –190 °F in blast freezers. Freeze for several hours before use.
Are reusable gel dry ice pack sheets safe for food contact? Yes. Most products are made from non toxic, food safe polymers and multi layer films and are manufactured under ISO 9001 and FDA certifications. Always check your supplier’s certifications and inspect sheets for punctures before use.
How long do gel dry ice pack sheets stay cold? It depends on sheet thickness and transit duration. A 12 mm sheet typically keeps products below –20 °C for up to 24 hours, an 18 mm sheet lasts around 48 hours and a 24 mm sheet can maintain –75 °C for up to 72 hours.
Can I cut a gel dry ice pack sheet to size? Yes. After hydration and freezing, cut along the seams to fit your container. Cutting through cells may cause leaks, so follow seam lines.
What’s the difference between gel pack, gel dry ice sheet and PCM sheet? Gel packs maintain 2–8 °C and melt into liquid; gel dry ice sheets freeze to –78.5 °C but remain flexible; PCM sheets use engineered phase change materials to hold narrow bands (2–8 °C or –20 °C) without dry ice. Choosing the right one depends on the required temperature range, duration and regulatory constraints.
How do I dispose of or recycle gel dry ice sheets? After use, thaw the sheet completely. For standard gels, puncture cells, seal the gel in a bag and place it in the trash. For biodegradable variants like Eco Gel™, compost the gel or incorporate it into garden soil following manufacturer guidelines. Recycle the plastic liner if accepted by local recycling programs.
Are gel dry ice sheets environmentally friendly? Traditional sheets are reusable and produce less waste than single use gel packs. New innovations such as Eco Gel™ and Terra Ice use biodegradable or compostable materials, reducing landfill waste and meeting growing consumer demand for sustainable packaging.
Conclusion and Recommendations
Reusable gel dry ice pack sheets offer a compelling combination of ultra cold performance, flexibility, and sustainability. Their super absorbent polymer cells can be hydrated, frozen to extreme temperatures and reused multiple times. Compared with dry ice, they eliminate hazardous handling and regulatory hurdles, while outperforming standard gel packs in cooling capacity and coverage. Market data show that reusable packs will dominate the gel ice pack sector in 2025, driven by demand in food, pharmaceutical and biologics logistics. Eco friendly innovations like Cryopak’s Eco Gel™ and Pelton Shepherd’s Terra Ice illustrate a sustainable future for refrigerants.
For your cold chain operations:
Assess your temperature and duration requirements. Match sheet thickness and weight to transit duration using the sizing guidelines provided.
Adopt reusable sheets to reduce costs and waste. Educate your team and customers on proper hydration, freezing and disposal to maximise reuse.
Integrate IoT monitoring. Use temperature data loggers to track conditions and comply with industry regulations, especially for pharmaceuticals and biologics.
Explore sustainable materials. Consider biodegradable or compostable gel sheets to meet environmental goals and consumer expectations.
By adopting reusable gel dry ice pack sheets and following these best practices, you can ensure safe, compliant and sustainable temperature control for your products.
About Tempk
At Tempk we specialise in designing and manufacturing innovative cold chain solutions. Our product range spans gel ice packs, hydrate dry ice packs, hot and cold therapy packs and fully insulated boxes. We invest in research and development to create multi layer materials and super absorbent polymers that deliver reliable temperature control. Many of our gel dry ice sheets achieve temperatures down to –190 °F and are ISO 9001 certified for food and pharmaceutical safety. We also offer eco friendly options, including biodegradable gels and recyclable films, to support sustainable logistics. Whether you’re shipping gourmet foods, clinical samples or high value biologics, Tempk provides tailored cold chain packaging that balances performance, safety and environmental responsibility.
Ready to improve your cold chain performance? Contact us for expert advice, sample kits or custom solutions. Our team can help you choose the right reusable gel dry ice pack sheet and design a packaging strategy that keeps your products safe and fresh while supporting your sustainability goals.
