Shipping frozen goods isn’t as simple as tossing a few ice cubes in a box. To ensure vaccines, biological samples and gourmet foods arrive at their destination fully frozen, you need ultra cold refrigerants that work reliably for days. Medical grade dry ice wrap — often sold as reusable sheets or cryoblock packs — meets this demand. It provides temperatures around –78 °C (–109 °F) without leaving liquid mess, holds its shape when frozen and can be cut to size. Using the right wrap can extend frozen life seven times longer than water ice and reduce waste compared with traditional blocks or gel packs. This guide explains what medical grade dry ice wrap is, how to pack with it safely, and why it matters for modern cold chain logistics. You’ll discover key steps to follow, regulatory considerations, comparisons with alternatives, and emerging innovations for 2025.
What is medical grade dry ice wrap and why use it? Explains composition, temperature performance and benefits using related long tail keywords like reusable dry ice sheets and ultra cold shipping wrap.
How do you package frozen goods using medical grade dry ice wrap? Provides a practical, step by step method covering pre freezing, PPE, layering and venting.
What safety and regulatory rules apply? Summarises hazardous material classification and packaging requirements from universities and safety organisations.
How does medical grade dry ice wrap compare with gel packs and other refrigerants? Presents a performance and safety comparison with gel packs, water ice and disposable blocks.
What are the latest market trends and innovations for 2025? Highlights market growth, new technologies and sustainability developments in the cold chain.
What Is Medical Grade Dry Ice Wrap and Why Use It?
Definition and Composition
Medical grade dry ice wrap refers to flexible sheets or multi cell packs that contain solid carbon dioxide encapsulated in FDA approved materials. Unlike loose pellets or slabs, these wraps are divided into small cells that freeze uniformly and can be cut to size while remaining flexible. Each cell holds a proprietary phase change formulation that maintains a temperature of –78 °C (–109 °F), the point at which carbon dioxide sublimates. Because the dry ice sublimates directly into gas, there is no moisture or residue, preventing contamination of medical specimens and food.
Non toxic and FDA approved: Reusable cryoblock packs use non toxic ingredients and materials approved for food and medical use.
Flexible and cuttable: Multi cell designs allow the wrap to be bent around odd shaped items and cut to size without losing integrity.
Reusable: These wraps can be refrozen and reused multiple times without degradation, offering sustainable alternatives to disposable blocks.
Longer cold life: According to Dry Chill, the packs can stay frozen up to seven times longer than water ice, making them ideal for long distance shipping.
Why Use Dry Ice Wrap?
Dry ice wrap offers several advantages over loose dry ice and gel packs:
Maintains ultra cold temperatures for critical goods. Medicines like mRNA vaccines need –70 °C conditions to stay viable. Wrap based packs maintain –78 °C for extended periods, ensuring product stability even during multi day transport.
Minimises product damage. The wrap design prevents direct contact between dry ice and goods, reducing the risk of freezing or freezer burn. The cell structure also cushions items, decreasing breakage.
Reduces sublimation loss. Bundled cells limit surface area exposed to air, slowing sublimation. This means less refrigerant is needed compared with loose pellets or nuggets.
Lower freight costs and waste. Because you can cut wraps to the exact size required, you avoid over packing and unnecessary weight. The reusable design further cuts waste.
Compliant with food and pharmaceutical regulations. The materials are rated for direct contact with food and medical products, supporting regulatory compliance for shipments.
Real World Scenario
Imagine shipping a batch of genetic test kits that must remain at –70 °C for 72 hours. Using loose dry ice pellets could lead to uneven cooling and dry ice dust contaminating swabs. Gel packs may only hold –15 °C. A 24 cell dry ice wrap fits around the kits, remains flexible and provides consistent –78 °C temperatures for up to 120 hours. The kits arrive intact and viable.
How to Package Frozen Goods Using Medical Grade Dry Ice Wrap
Proper packaging ensures that frozen goods remain cold and that shipping personnel stay safe. The following method blends field tested best practices with new recommendations for 2025:
Step by Step Packing Instructions
Pre freeze the product. Freeze the goods to at least –20 °C for 24 hours. Starting with frozen goods reduces the cooling burden on the dry ice wrap.
Wear protective equipment. Dry ice is extremely cold and can cause frostbite. Use insulated gloves, goggles and an apron.
Prepare the wrap. Lay the medical grade dry ice wrap flat in a commercial freezer (–20 °C to –30 °C) until all cells are solid. Do not cut until frozen. For shipments requiring partial wrap coverage, cut along sealed seams to create the needed size.
Line the shipping container. Choose an insulated container with adequate strength (e.g., a 30 mm expanded polystyrene [EPS] box inside a corrugated carton). Do not use plastics that become brittle at low temperatures. Fill empty spaces with cardboard or padding.
Place the product in the center. Wrap temperature sensitive products in two watertight plastic bags or add absorbent material with a plastic liner to contain condensation or leaks.
Wrap and top load dry ice. Place the frozen wrap around and above the product. Position additional dry ice wraps or blocks on top of the product; cold air sinks, so top loading improves cooling efficiency. Avoid placing refrigerant at the bottom.
Vent and seal. Do not seal containers airtight. Packages must allow carbon dioxide gas to vent. Leave small holes (≈6 mm) in the container’s lid or use vented lids. Tape only the carton flaps, not the vent holes.
Label and document. Label the outer carton with the Class 9 “dry ice” hazard diamond and write “UN 1845, Carbon Dioxide, Solid” plus net weight in kilograms【145967662472752†L114-L121】. Include shipper and recipient addresses.
Add documentation. For air shipments, fill out the air waybill or shipping document, specifying the weight of dry ice and number of packages.
Plan for transit time. Use the rule of thumb: Dry ice sublimates at about 5–10 pounds (2.3–4.5 kg) every 24 hours depending on container insulation. For extended travel, pack extra wrap or blocks to account for delays.
Packing Checklist and Considerations
| Action | Reason | Your Benefit |
| Pre freeze goods and wrap | Reduces heat load on refrigerant | Maximises wrap efficiency |
| Use insulated, strong containers | Prevents breakage and controls heat exchange | Protects product integrity |
| Fill empty space with cushioning | Minimises air volume to slow sublimation and prevents movement | Ensures steady temperature and product stability |
| Wrap the refrigerant in paper or carton | Slows sublimation and prevents excess space | Extends cooling duration |
| Vent container, avoid airtight seal | Allows CO₂ to escape and prevents explosion | Enhances safety and regulatory compliance |
Decision Tool: Calculate Dry Ice Wrap Quantity
You can estimate the amount of dry ice wrap needed using a simple formula. Multiply the mass of your frozen goods by 1.1 (to account for heat of fusion) and by the number of transit days; then add a 15 % safety buffer:
Dry ice required (kg) = [Product mass (kg) × 1.1 × Transit days] × 1.15
Example: Shipping 8 kg of insulin for 3 days → 8 × 1.1 × 3 × 1.15 ≈ 30 kg of dry ice wrap. Adjust quantity based on the insulation quality and ambient temperature. This tool helps avoid over packing (wasting money) or under packing (risking thaw).
Safety and Regulatory Considerations
Medical grade dry ice wrap is safe when handled properly. However, dry ice is classified as a miscellaneous hazardous material (Class 9) and is regulated by the U.S. Department of Transportation (DOT) and the International Air Transport Association (IATA). Non compliance can result in fines and shipment delays.
Hazards Associated with Dry Ice
Explosion hazard: Sublimating dry ice releases large volumes of CO₂ gas. Airtight containers can explode if gas is trapped.
Suffocation hazard: Carbon dioxide displaces oxygen in enclosed spaces, leading to potential asphyxiation.
Contact hazard: Direct skin contact causes severe frostbite.
Key Regulatory Requirements
Training – Anyone packaging or signing shipping papers for dry ice must receive hazard communication training. Certification must be renewed every two years or as regulations change.
Venting – Packaging must allow gas to escape. Do not seal dry ice in containers with airtight lids or sealed plastic bags.
Package strength – Containers must withstand loading and unloading, vibration and temperature fluctuations.
Materials – Avoid plastics that become brittle or permeable at –78 °C. Use commercially available dry ice shipping containers.
Labeling – Display the Class 9 hazard label, UN 1845 and net weight of dry ice. Place labels on a vertical side of the package.
Documentation – The air waybill must state the number of packages and net weight of dry ice.
Quantity limits – The maximum allowable net quantity per package is 200 kg. Individual airlines may impose stricter limits; always check current carrier policies.
Safety Tips for Handling Dry Ice Wrap
Use protective gloves and eye protection whenever touching the wrap.
Never consume or ingest dry ice; seek medical help immediately if ingestion occurs.
Store in ventilated areas; do not keep dry ice in unventilated rooms or vehicles.
Avoid placing dry ice directly against products. Wrap the wrap in paper or use separators to prevent freeze burns.
Do not ship over weekends when delivery delays are likely.
Comparing Medical Grade Dry Ice Wrap With Gel Packs and Other Refrigerants
Choosing the right refrigerant depends on target temperature, shipment duration, cost and safety. The table below summarises how medical grade dry ice wrap compares with gel packs, water ice and disposable dry ice blocks.
| Refrigerant | Temperature range | Duration | Reuse cycles | Safety concerns | Typical applications |
| Medical grade dry ice wrap | –78 °C constant | Up to 120 h (can be 7× longer than ice) | 100+ (reuse; flexible) | Requires gloves; CO₂ venting; avoid airtight containers | Vaccines, biologics, high value seafood |
| Disposable dry ice blocks | –78 °C constant | 24–96 h depending on size | Single use | Frostbite and suffocation risk; fixed shape | Meat shipments, dry ice fog effects |
| Gel packs | –12 °C to –18 °C (freezer temperature) | 24–48 h | 30+ reuses with <10 % capacity loss | Non hazardous; safe for handling | Food delivery, insulin transport |
| Water ice | 0 °C | 12–24 h | Single use | Melts to liquid causing leaks | Picnic coolers, beverage cooling |
| Phase Change Materials (PCM) | Custom (–20 °C to +25 °C) | 48–144 h | 100+ | Non hazardous; some require disposal protocols | Pharmaceutical shipments, last mile delivery |
Key takeaways:
Dry ice wrap maintains the coldest temperatures and is necessary for goods requiring deep freeze (–70 °C or lower). Gel packs cannot achieve this range.
Gel packs and PCMs are safer and easier to handle but suitable only for chilled or lightly frozen goods.
Wraps are reusable and flexible, reducing waste and costs over time.
Practical Tips When Choosing Refrigerants
For ultra cold medical shipments like mRNA vaccines or monoclonal antibodies, choose medical grade dry ice wrap plus additional blocks.
For frozen meals and desserts, use a combination of gel packs and small dry ice wraps to maintain –20 °C while controlling costs.
For last mile delivery in warm climates, phase change materials with a –15 °C melting point may suffice. Combine with digital temperature loggers for compliance.
Case study: A biotechnology company needed to ship 2 kg of gene therapy samples from California to Germany within 72 hours. They used two 24 cell medical grade dry ice wraps around the samples and added one 600 g cryoblock on top. By venting the container and using an EPS cooler, they maintained –75 °C for the entire transit. Regulatory labels prevented customs delays and all samples passed quality control upon arrival.
Latest Developments and Market Trends for 2025
Market Growth and Demand Drivers
The cold chain logistics market is expanding rapidly, driven by global pharmaceutical growth, e commerce food delivery and vaccine distribution. Precedence Research reports that the global cold chain logistics market size was USD 436.3 billion in 2025 and is forecast to reach USD 1,359.78 billion by 2034, an annual growth rate of 13.46 %. Within this market, the dry ice segment held the highest technological share (55.16 % in 2024), reflecting ongoing reliance on ultra cold shipping solutions.
Key growth factors include:
Rising pharmaceutical and biotechnology shipments. The need to transport biologics and gene therapies at –70 °C or lower drives demand for medical grade dry ice wraps.
Growth in frozen food e commerce. Consumers increasingly order frozen meals and seafood online; maintaining product quality requires reliable ultra cold wraps.
Stringent food and drug regulations. Regulatory agencies require validated temperature control; dry ice wraps help meet these standards.
Adoption of AI and IoT in the cold chain. Real time temperature monitoring and route optimisation reduce excursions and spoilage.
Innovations in Dry Ice Wrap Technology
Recent innovations improve the performance and sustainability of dry ice wraps:
Self healing gels and advanced films. Some manufacturers embed self healing polymers in the cell structure, sealing punctures automatically to prevent CO₂ leaks (experimental but anticipated to become commercial by 2025).
Hybrid PCM/dry ice designs. Combining phase change materials with dry ice slows sublimation and reduces the weight of pure dry ice needed.
Smart wraps with temperature logging. New wraps incorporate low profile dataloggers that track temperature and provide Bluetooth alerts. This helps comply with FDA and EMA record keeping requirements.
Sustainable materials. Manufacturers are developing biodegradable wrap casings using plant based polymers. Some options decompose within 90 days after disposal.
Digital calculators and AI planning tools. Online tools estimate required dry ice mass, route options and regulatory compliance (as described in the earlier formula). These reduce shipping errors and costs.
Sustainability Considerations
Dry ice production relies on capturing carbon dioxide from industrial processes. Supply chain disruptions and rising CO₂ prices have led to periodic shortages, so efficiency matters. Using medical grade wraps helps by reducing sublimation loss and enabling reuse, thereby lowering the total amount of dry ice consumed. However, users should be aware that CO₂ supply growth lags demand: global dry ice consumption has risen by roughly 5 % annually while supply increases at only about 0.5 %. Investing in hybrid or reusable refrigerants can mitigate future shortages.
Frequently Asked Questions (FAQ)
Why choose medical grade dry ice wrap over loose dry ice?
Wraps provide uniform cooling, prevent direct contact with products and can be cut to size. They also reduce sublimation and improve safety compared with loose pellets.
How long does medical grade dry ice wrap keep items frozen?
Depending on thickness and insulation, wraps can maintain –78 °C for up to 120 hours — significantly longer than water ice or gel packs.
Do I need special training to ship with dry ice?
Yes. Both DOT and IATA regulations require training before you can pack or sign shipping documents for dry ice. Training must be renewed every two years.
Can dry ice wrap make goods too cold?
If items are sensitive to ultra cold temperatures, place a barrier (like a gel pack or phase change material) between the wrap and the product. However, premium wraps maintain a narrow temperature variation (<1 °C) at –70 °C.
What should I do with used wraps?
Allow residual dry ice to sublimate in a ventilated area. Inspect the wrap for leaks or damage. Most medical grade wraps can be reused over 100 times; discard if cells are punctured or if weight loss exceeds 10 %.
Summary and Recommendations
Medical grade dry ice wrap is an essential tool for shipping frozen goods that require ultra cold temperatures. Its multi cell, flexible design allows precise sizing, reusability and long hold times. When used correctly, it can keep products at –78 °C for days, outperforming gel packs and water ice. To ensure safe and compliant shipments:
Follow proper packing steps: Pre freeze goods, wear protective gear, use insulated containers and vent packages. Position dry ice wraps above products and avoid sealing containers airtight.
Use the right quantity of wrap: Estimate dry ice mass using the provided formula and adjust for transit time. Over packing wastes money while under packing risks spoilage.
Comply with regulations: Label packages with the Class 9 hazard diamond and record net weight【145967662472752†L114-L121】. Ensure trained personnel handle packaging and documentation.
Compare alternatives: For shipments requiring only chilled conditions, gel packs or PCMs may suffice. For ultra cold shipments, dry ice wrap is irreplaceable.
Plan for sustainability: Reuse wraps whenever possible and explore hybrid PCM/dry ice solutions. Monitor dry ice supply trends and adjust procurement strategies accordingly.
About Tempk
We are a cold chain technology company dedicated to designing and manufacturing advanced refrigerants and insulated packaging solutions. Our medical grade dry ice wraps and hybrid PCM systems are developed using proprietary phase change formulations and FDA approved materials. We focus on safety, reusability and environmental stewardship. Our products help clients in pharmaceuticals, food logistics and biotechnology ship temperature sensitive goods reliably. Contact us to discuss how we can support your cold chain needs.
Call to action: Ready to keep your frozen products safe? Reach out to our team for personalised recommendations or request a sample pack today.
