How Do Medical Grade Dry Ice Sheets Ship Vaccines?
Introduction: When you’re shipping high value vaccines across the country, temperature matters more than anything. A medical grade dry ice sheet for vaccine shipping can maintain ultra cold conditions of –70 °C to –80 °C required for mRNA vaccines, and each pound lasts roughly 18–24 hours. In this guide you’ll discover what makes dry ice sheets “medical grade,” how to prepare and handle them safely, and why new technologies and sustainable materials are transforming vaccine cold chain logistics in 2025.
What is a medical grade dry ice sheet and why is it essential for vaccine shipping?
How can you prepare, size and pack dry ice sheets to maintain vaccine potency?
What safety, regulatory and compliance rules govern the use of dry ice in vaccine transport?
How are 2025 trends like IoT monitoring, reusable packaging and blockchain impacting vaccine shipments?
Which criteria help you choose the best dry ice sheet for your vaccine cold chain?
What Is a Medical Grade Dry Ice Sheet and Why Is It Critical for Vaccine Shipping?
Medical grade dry ice sheets are specialized refrigerant mats made from sterile materials and filled with pure carbon dioxide powder. They’re engineered to meet pharmaceutical standards for cleanliness and are tested to ensure they don’t introduce contaminants into vaccine packages. Unlike consumer grade ice packs, these sheets provide ultra low temperatures without leaving moisture. They rely on dry ice—solid carbon dioxide—that sublimates directly into gas at –78.5 °C. This process absorbs heat and keeps vaccines cold without melting water. For mRNA vaccines that must be stored between –70 °C and –80 °C, dry ice sheets are indispensable. Other vaccines, such as inactivated vaccines, can be kept at 2 °C to 8 °C, so medical grade dry ice isn’t always necessary.
Distinguishing Medical Grade Dry Ice from Standard Dry Ice
Medical grade dry ice is manufactured from high purity CO₂ and produced in facilities that adhere to Good Manufacturing Practices. It undergoes additional filtration and quality testing to ensure no oil residues or contaminants remain. The sheets themselves are typically made from pharmaceutical grade polymer film and absorbent matrix, which are sterilized to reduce microbial contamination. Standard dry ice may not meet these stringent requirements and is often packaged in pellets or blocks that leave residue or dust, which can contaminate vaccine vials or compromise sterility.
Vaccine Temperature Requirements and Dry Ice Benefits
| Vaccine type | Temperature range | Dry ice sheet advantage | Real world implication |
| mRNA (e.g., Pfizer BioNTech) | –70 °C to –80 °C | Maintains ultra cold temperatures for up to 18–24 hours per 5–10 lb of dry ice | Ensures vaccine potency during cross country shipping. |
| Moderna (frozen) | –50 °C to –15 °C | Dry ice sheets can pre chill shipments but should not store vaccine below –50 °C; avoid direct contact | Use dry ice only for transit; transfer to a freezer at destination. |
| Inactivated vaccines | 2 °C to 8 °C | Gel packs or PCMs suffice; dry ice may over freeze | Prevents unnecessary freezing damage; choose appropriate refrigerant. |
| Biologic samples | –20 °C or lower | Flexible dry ice sheets provide consistent cold without moisture | Protects proteins and cells from temperature spikes. |
Medical grade dry ice sheets offer a large surface area to wrap around vaccine trays or ultra cold boxes, providing even cooling and avoiding cold spots. Their sterile construction ensures they are safe for use in regulated pharmaceutical logistics.
How to Prepare and Use Medical Grade Dry Ice Sheets Correctly
Preparing dry ice sheets for vaccine shipments is a multi step process. Proper hydration, freezing and packing will maintain the cold chain and minimize product loss.
Step by Step Preparation Guide
Hydrate the sheet: Place the dry ice sheet in a clean basin of water and allow it to absorb water. Depending on the product, hydration may take anywhere from 15 minutes to 24 hours—check the manufacturer’s instructions.
Freeze at the right temperature: After hydration, freeze the sheet at least 10 °C below the targeted ultra cold temperature; for mRNA vaccines, this means placing the sheet in a –85 °C freezer if available.
Pre condition the packaging: Pre chill the insulated container and vaccine trays. Pre cooling reduces thermal shock and slows down dry ice sublimation.
Calculate dry ice quantity: Use a 5–10 lb per 24 hour guideline. Mercury’s 2025 dry ice shipping instructions note that dry ice evaporates at 5–10 lb per 24 hours and recommend at least 5–10 lb per day for shipments up to 12.5 lb. For vaccine shippers, calculate the volume and weight of the vaccine and insulation to determine the required dry ice.
Pack in layers: Place a layer of dry ice sheet on the bottom of the insulated box, arrange the vaccine cartons on top, and then cover with another sheet. Include side sheets if shipping to hot climates.
Vent the container: Ensure that the shipping container is not airtight. Leave a small gap or use a vented lid. According to CDC guidelines for portable vaccine containers, packages must allow gas to escape to prevent pressure buildup.
Best Practices for Vaccine Shipping Using Dry Ice Sheets
Choose appropriate insulation: Ultra cold vaccine shipments rely on qualified containers and packouts. The CDC recommends using portable vaccine refrigerators or qualified containers with phase change materials (PCMs) or dry ice. Avoid using standard food coolers as they may not provide adequate insulation.
Use data loggers: Install a digital data logger (DDL) with a probe placed near the vaccine vials to continuously monitor temperature. The CDC requires DDLs for vaccine transport and recommends checking and recording temperatures at least twice daily.
Limit exposure: For mRNA vaccines, the total time for transport and clinic work should be no more than eight hours. After transport, promptly transfer vaccines to an ultra cold freezer or follow manufacturer guidance for thawing and administration.
Avoid direct contact: Do not place vaccine vials directly on dry ice. Use corrugated cardboard or foam to create separation and prevent vials from freezing solid. Moderna’s storage summary cautions against storing vaccines with dry ice or below –50 °C.
Replenish dry ice: For long shipments, plan to replenish the dry ice every five days (or according to the container’s manufacturer guidelines) to maintain ultra cold temperatures. Ultra cold storage planning documents note that shipping containers must be regularly replenished with fresh dry ice and stored in well ventilated areas.
Choosing the Right Size and Configuration
Dry ice sheets come in various cell counts and dimensions. A medical grade sheet may have 24, 48 or more cells, each containing sterile CO₂ powder. To determine the best size:
Estimate payload volume: Calculate the combined volume of vaccine vials, trays and protective materials. Use the rule of 5–10 lb dry ice per 10 L of volume per day.
Consider the number of layers: In extremely cold shipments, multiple layers of dry ice sheets may be required to create an evenly distributed cold zone.
Custom cut for fit: Choose sheets that can be cut or folded without damaging the cells. This flexibility ensures the sheet wraps tightly around vaccine payloads, minimizing dead air space.
A Quick Self Check Tool
Before shipping, run through this five point readiness check to avoid common mistakes:
Record dry ice quantity: Have you measured the weight of dry ice and verified that it meets your 24 hour requirement?
Verify venting: Is the lid vented or slightly ajar to allow CO₂ gas to escape?
Label properly: Does the package label include “Dry Ice, UN 1845” and the net weight of the dry ice?
Data logger installed: Have you placed a digital data logger probe near the vaccines and ensured it is active?
Team training: Are all handlers trained in dry ice safety and emergency procedures?
If you answer “no” to any question, revisit the previous steps before sealing the box. This simple checklist is an interactive tool to help you reduce risk and maintain compliance.
Safety, Regulatory and Compliance Guidelines
Working with dry ice is inherently risky. The combination of extreme cold and carbon dioxide gas can pose serious hazards if mishandled. Regulatory agencies such as the Department of Transportation (DOT), International Air Transport Association (IATA) and local health departments have detailed rules for shipping hazardous materials. Ignoring these regulations can lead to fines, shipment delays or compromised vaccines.
Understanding the Hazards
| Hazard | Description | Preventive measure |
| Asphyxiation | Dry ice sublimates into CO₂ gas, which can displace oxygen in enclosed spaces, causing dizziness or suffocation. | Handle dry ice in well ventilated areas and avoid transporting containers in unventilated vehicles or tight rooms. |
| Frostbite and burns | Contact with surfaces at –78 °C can cause severe skin damage. | Wear waterproof insulated gloves, safety goggles and long sleeves when handling dry ice. |
| Pressure buildup | CO₂ gas can expand in sealed containers and cause packages to explode. | Never seal dry ice in an airtight or glass container; ensure packages allow gas to escape. |
| Environmental harm | Although dry ice is produced from captured CO₂, its sublimation releases greenhouse gas into the atmosphere. | Use only the necessary amount of dry ice and choose suppliers that capture CO₂ from industrial processes. |
| Improper storage | Storing dry ice in refrigerators or freezers can damage equipment and trap CO₂. | Store dry ice in insulated containers in ventilated areas; do not put it in standard freezers. |
Regulatory Requirements for Vaccine Shipping
UN 1845 labeling: Packages containing dry ice must display the “Dry Ice (Carbon Dioxide, Solid)” designation along with the net weight of dry ice. For air shipments, a Class 9 hazard label is required.
Quantity limits: Keep total dry ice per package below 200 kg to avoid special permitting. Smaller shipments typically require only 5–10 lb but must still comply with labeling rules.
IATA Packing Instruction 904: Air shipments must allow for CO₂ venting and include documentation specifying the amount of dry ice and handling instructions.
Carrier specific policies: Some carriers restrict dry ice shipments to certain services or require separate hazardous materials contracts. Always check with your carrier before shipping.
Training and certification: Staff packing and shipping vaccines must be trained in handling hazardous materials and may need certification. For example, the Pfizer BioNTech handling guide requires personnel to take dry ice handling training.
Safety Tips for Handlers
Ventilate the workspace: Dry ice releases CO₂ gas at room temperature. Use shipments in open areas; do not open containers in small coolers or confined spaces.
Wear proper PPE: Use waterproof insulated gloves, safety goggles and long sleeves to protect against burns.
Handle heavy containers carefully: Vaccine thermal shippers can weigh up to 36.5 kg (81 lb). Use proper lifting techniques and team assistance to prevent injury.
Follow manufacturer instructions: Some vaccines, such as Moderna’s, should not be stored with dry ice or below –50 °C. Always refer to manufacturer guidelines for storage and thawing.
Plan for disposal: Let unused dry ice sublimate in a well ventilated area; do not dispose of dry ice in trash bins, drains or confined spaces.
Environmental Impact and Sustainability Considerations
While dry ice is produced by compressing recovered CO₂, its use still releases carbon dioxide into the atmosphere. Vaccine producers and shippers increasingly prioritize sustainability. Here’s how to minimize environmental impact:
Use recycled CO₂: Source dry ice from suppliers that capture CO₂ from industrial processes such as ethanol or ammonia production. This practice doesn’t add new CO₂ to the atmosphere but repurposes existing emissions.
Optimize quantity: Avoid over packing. The rule of 5–10 lb per 24 hours ensures you use only as much dry ice as necessary.
Combine with phase change materials: Hybrid solutions using PCM plates for –20 °C or +2 °C along with dry ice reduce the amount of CO₂ needed while maintaining temperature stability.
Choose reusable packaging: Premium dry ice packs can be reused 100–200 times, reducing waste and cost over time. Reuse reduces the environmental footprint compared with single use dry ice blocks.
Capture CO₂ emissions: Some facilities install CO₂ capture systems to collect gas released from sublimation. While not yet common in small scale shipments, these technologies are emerging.
Eco Friendly Product Design
Medical grade dry ice sheets are evolving. New products use biodegradable outer films and plant based insulation to reduce plastic waste. Manufacturers also offer low dust CO₂ powders to minimize particulate contamination. By choosing eco friendly options and reusing your dry ice sheets when possible, you contribute to a greener vaccine supply chain.
2025 Trends and Innovations in Vaccine Cold Chain Logistics
The cold chain industry is undergoing rapid change, driven by the need for large scale vaccine distribution and improved sustainability. Here are the major trends shaping 2025 and beyond:
Real Time Temperature Monitoring and IoT Integration
Advanced IoT sensors embedded in shipping containers continuously monitor temperature, humidity and location. These devices send real time alerts if the internal temperature deviates from the acceptable range, allowing shippers to intervene before vaccines become compromised. The Tempk 2025 guide notes that digital data loggers and real time monitors are now standard for vaccine shipments and help meet regulatory requirements.
Smart Shipping Containers and Blockchain Traceability
Specialized ultra cold shippers, like those developed by Single Use Support, can maintain temperatures below –60 °C for at least six days using dry ice. These containers often integrate blockchain technology, creating an immutable record of each shipment’s conditions and chain of custody. Blockchain enhances transparency and enables quick recalls if problems are detected.
Hybrid Cooling Systems and Extended Hold Time
Hybrid solutions combine dry ice with PCMs and gel packs to stabilize temperature curves. For shipments where vaccines need to transition from ultra cold to refrigerated conditions, hybrid systems gradually reduce temperature and avoid sudden thermal shocks. Multi layer packs can extend hold time to 72–120 hours, reducing the need for frequent replenishment.
Reusable and Sustainable Packaging
Reusable cold chain packaging is gaining popularity. The reusable cold chain packaging market is expected to grow from USD 4.97 billion in 2025 to USD 9.13 billion by 2034, driven in part by vaccine distribution. Companies are investing in insulated boxes made of recycled materials, reusable vacuum insulated panels and modular designs that accommodate different refrigerants.
Market Growth and Vaccine Demand
Large scale vaccination campaigns continue to drive demand for ultra cold logistics. Analysts estimate the global vaccine cold chain logistics market to be worth over USD 3 billion in 2024, with growth projected through 2030. This growth is fueled not only by COVID 19 boosters but also by new mRNA vaccines for influenza, RSV and personalized therapeutics. To meet this demand, shippers must adopt cutting edge technologies, optimize packaging and ensure compliance with ever evolving regulations.
How to Choose the Best Medical Grade Dry Ice Sheet for Vaccine Shipping
Selecting the right dry ice sheet for vaccine transport requires balancing performance, cost, regulatory compliance and sustainability. Here’s a decision framework to guide you:
Assess your vaccine’s temperature needs: Determine whether you require ultra cold (–70 °C), frozen (–20 °C) or chilled (2–8 °C) conditions. For ultra cold requirements, choose thicker dry ice sheets with more cells.
Calculate transit time and environment: Consider the total time from pickup to delivery, including potential delays. Add additional dry ice for long distances or hot climates. Use the 5–10 lb per 24 hours guideline to estimate quantity.
Check sterility and certification: Ensure the dry ice sheets are manufactured in ISO certified facilities and come with certificates of analysis verifying sterility.
Verify compatibility with your container: Choose sheets that fit your thermal shipper’s dimensions. Some containers require specific shapes or sizes to maximize contact with the payload.
Consider reusability: If you ship regularly, invest in reusable dry ice sheets that can withstand 100–200 cycles. Reusable sheets cost more upfront but save money over time.
Look for eco friendly materials: Opt for sheets made with biodegradable films, recycled paper or plant based insulation. Manufacturers like Tempk offer biodegradable kraft paper coatings to reduce plastic waste.
Check supplier support: Choose suppliers that offer training, technical documentation and customer service. Reliable support helps you stay compliant with regulations and avoid shipment delays.
Comparing Medical Grade Dry Ice Sheets with Alternatives
| Feature | Medical Grade Dry Ice Sheet | Standard Dry Ice Pellets | Gel/PCM Packs | Meaning for your vaccine shipment |
| Sterility | Produced under GMP with sterile materials | May contain dust and oil residues | Typically non sterile | Ensures vaccines are not contaminated. |
| Temperature range | –78.5 °C to –60 °C or customized | –78.5 °C; direct contact may damage vials | 2 °C to 8 °C or –20 °C depending on formulation | Use dry ice only when vaccines need ultra cold storage; choose gel/PCM for routine vaccines. |
| Ease of handling | Flexible sheet wraps around payload; less mess | Pellets or blocks require scooping; produce more CO₂ gas | Easy to handle but cannot achieve ultra cold temps | Sheets reduce handling time and minimize exposure. |
| Reusability | Can be reused until damaged; premium sheets last 100–200 cycles | Single use; not sterile | Reusable but limited to moderate temps | Reusable sheets lower total cost and waste. |
| Regulatory status | Classified as hazardous (UN 1845) requiring labeling and training | Same as sheet | Generally non hazardous | Plan for training and documentation if using dry ice. |
| Environmental impact | CO₂ emissions from sublimation; can be mitigated with recycled CO₂ and hybrid packaging | High emissions; often single use | Less CO₂ but may contain petroleum gel | Eco friendly sheets and hybrid solutions reduce footprint. |
Practical Tips and User Advice
For local vaccine clinics: Use qualified containers with PCMs for local transport; avoid dry ice unless vaccines need ultra cold conditions. Keep transit time below eight hours and record temperatures regularly.
For long distance shipments: Use medical grade dry ice sheets in combination with thermal shippers. Plan for replenishment of dry ice every five days. Use IoT sensors and a web dashboard to monitor temperature in real time.
For international shipments: Check the destination country’s import regulations. Some countries have strict limits on dry ice shipments; ensure documentation is complete and packages are properly labeled.
Real World Example: A regional health authority needed to ship mRNA vaccines to remote clinics over a two day journey. By using a medical grade dry ice sheet layered above and below the vaccine trays and employing a data logger for monitoring, they maintained temperatures between –75 °C and –70 °C for 48 hours. They replenished dry ice at a midway hub and followed training guidelines for handling. As a result, all vaccines remained viable and no doses were wasted.
Frequently Asked Questions
Q1: How much dry ice do I need for a vaccine shipment?
Plan for 5–10 lb per 24 hours for every 10 L of volume. This guideline ensures the ultra cold temperature is maintained throughout transit. Adjust for shipment weight, insulation quality and ambient temperature.
Q2: Can I reuse medical grade dry ice sheets?
Yes. Premium sheets are designed to be reused up to 100–200 cycles. Inspect the sheet after each use for damage or contamination. If the sheet is torn or no longer sterile, dispose of it responsibly.
Q3: Is it safe to ship vaccines with dry ice on airplanes?
Yes, but you must comply with IATA Packing Instruction 904. Packages must allow gas release, include UN 1845 labels and indicate the net weight of dry ice. Some carriers limit the amount of dry ice per package; check with your airline.
Q4: How do I dispose of leftover dry ice after shipping?
Let unused dry ice sublimate in a well ventilated area away from children or pets. Never place dry ice in trash bins, drains or confined spaces where gas could accumulate.
Q5: What happens if my vaccine shipment arrives with a broken dry ice sheet?
If the sheet is torn or no longer producing cold, immediately transfer the vaccines to a qualified ultra cold freezer and contact your carrier. Document the incident using your temperature data logs and report to the vaccine manufacturer or health authority.
2025 Market Insights and Future Outlook
The vaccine cold chain industry is entering a period of rapid innovation and growth. While the global reusable cold chain packaging market is predicted to reach USD 9.13 billion by 2034, vaccine specific logistics are also scaling. Governments and pharmaceutical companies are investing in dedicated ultra cold infrastructure, including modular ULT freezers, micro fulfillment centers and on demand manufacturing plants. As more mRNA vaccines enter the market, demand for medical grade dry ice sheets will remain strong. Meanwhile, research into new refrigerants like solid nitrogen and advanced PCMs may eventually reduce reliance on CO₂. To stay competitive, shippers should monitor regulatory updates, invest in sustainability and adopt digital monitoring tools.
Summary and Recommendations
Medical grade dry ice sheets are a critical tool for vaccine shipping. They deliver ultra cold temperatures (–78 °C) necessary for mRNA vaccines, provide stable cooling for 18–24 hours per 5–10 lb and maintain sterility throughout the cold chain. To use them effectively:
Prepare and pack properly: Hydrate and freeze the sheets according to manufacturer instructions, and use the 5–10 lb per 24 hours guideline to estimate quantity. Pack in layers and ventilate the container.
Follow safety rules: Use PPE, handle dry ice in well ventilated areas and label packages with UN 1845 and net weight. Replenish dry ice as needed and store containers in ventilated spaces.
Choose the right product: Select medical grade sheets that are certified sterile, fit your container and support reuse. Consider eco friendly options with biodegradable films and recycled CO₂.
Leverage technology: Use IoT sensors, data loggers and blockchain systems to monitor shipments in real time and ensure compliance.
By following these recommendations and staying informed about industry trends, you can safeguard your vaccine shipments, reduce waste and contribute to a more sustainable cold chain.
Recommended Next Steps
Evaluate your vaccine logistics workflow: Identify where temperature excursions or compliance issues occur.
Contact a trusted supplier: Source medical grade dry ice sheets and request documentation on sterility and CO₂ sourcing.
Train your team: Provide hands on training in dry ice handling, packaging and regulatory compliance.
Implement monitoring tools: Invest in digital data loggers and IoT devices to track temperature and location in real time.
Review sustainability: Explore reusable packaging and hybrid cooling solutions to reduce carbon footprint.
About Tempk
Tempk is a leading provider of cold chain packaging solutions for pharmaceuticals, biotechnology and food industries. We specialize in medical grade dry ice sheets and innovative cooling products that meet stringent regulatory requirements. Our R&D team develops eco friendly materials, smart temperature monitoring and hybrid packaging systems, ensuring that your vaccines arrive safely and sustainably. With decades of experience and a commitment to quality, we partner with clients worldwide to design customized cold chain solutions.
Call to Action: Ready to optimize your vaccine shipping? Contact Tempk for expert advice, custom medical grade dry ice sheets and comprehensive cold chain support.
