How dry ice containers & pack sheets power cold chain
Dry ice containers and pack sheets aren’t just industrial curiosities — they’re the unsung heroes of ultra cold logistics. Keeping shipments at –78.5 °C (–109°F) requires materials that maintain a subzero environment while allowing carbon dioxide gas to escape. One pound of dry ice can sublimate into 8.3 ft³ of CO₂ and loses about 3–8 % of its mass each day, so packing it correctly is essential. This guide helps Du choose the right container or sheet, calculate the correct dry ice weight, follow regulations, and explore the latest 2025 innovations to keep your cargo cold and compliant.
How do dry ice containers and pack sheets work? – learn the difference between insulated boxes and flexible sheets, why ventilation matters and how sublimation keeps goods dry.
Wie viel Trockeneis brauchen Sie? – use simple formulas and payload specific guidelines to estimate ice for vaccines, seafood or desserts.
What regulations apply in 2025? – understand DOT/IATA rules, hazard classes, weight limits and triple packaging requirements.
When should you choose gel packs or PCMs instead? – compare dry ice to other refrigerants on temperature range, reusability and hazard classification.
What are the key trends shaping cold chain packaging? – explore sustainability efforts, IoT enabled smart containers and reusable systems as the market grows beyond USD 4.97 billion.
What are dry ice containers & pack sheets and how do they work?
Dry ice containers and pack sheets are purpose built packaging solutions that safely harness the extreme cold of solid carbon dioxide. A dry ice container is typically a rigid, insulated box made from high density polyethylene (HDPE) or expanded polystyrene (EPS) with thick walls and vent ports. These features slow down sublimation while allowing CO₂ gas to escape. Pack sheets or wraps are thinner, flexible pouches containing pellets or slices. They conform around products, providing targeted cooling without the bulk of a large box. Both formats prevent condensation because dry ice sublimates directly into gas rather than melting into water, ensuring your cargo stays dry and intact.
Why sublimation makes dry ice different
Sublimation is the process where a solid turns directly into a gas without passing through a liquid phase. At atmospheric pressure, dry ice maintains a temperature near –78 °C. When it absorbs heat, it doesn’t melt; it simply disappears into CO₂ gas. This unique property keeps shipments dry, avoids soggy packaging and prevents water damage. Jedoch, it also means that containers must be vented. If a box is sealed tight, pressure builds up and can cause ruptures. Pack sheets often include breathable membranes, while rigid containers incorporate vent holes or self venting lids. Venting isn’t optional — regulations require it for safety. Because the gas is heavier than air, work in well ventilated areas and never inhale CO₂ vapors.
Choosing the right dry ice form
Different dry ice formats behave differently. Blöcke are large slabs that sublimate slowly, making them ideal for long duration shipments. Pellets Und nuggets offer faster cooling but have a higher surface area to mass ratio, so they disappear sooner. Slices provide a balance of coverage and longevity, fitting neatly between products or inside pack sheets. Dry ice snow has the fastest sublimation rate and is generally used for quick, flash freezing applications rather than shipping. Choosing the right format helps you manage cooling power, duration and cost.
| Dry ice type | Typical size | Sublimation speed | Beste Verwendung |
| Snow | Powder like particles | Fastest; very short shelf life | Flash freezing and blasting |
| Pellets | 3 mm – 6 mm | Schnelle Sublimation; quick cooling | Food processing, small pack sheets |
| Nuggets | 6 mm – 19 mm | Average sublimation; medium shelf life | Shipping small packages over short distances |
| Slabs/slices | ≈ 19 mm thick | Slow sublimation; long shelf life | Airline catering, long shipping lanes |
| Blöcke | Groß (Z.B., 250 × 250 × 125 mm) | Slowest sublimation, längster Halt | Pallet shipments, industrial applications |
Practical tips and real world use cases
Vaccine distribution: For ultra cold vaccines requiring temperatures below –60 °C, use a high density EPS or vacuum insulated container with thick walls. Place dry ice blocks on all sides, pre condition the box, and add temperature monitors. A biotech firm shipping viral vectors maintained –65 °C to –70 °C for 72 hours using blocks and pellets together.
Seafood or meat shipments: Pellets or nuggets wrapped in pack sheets are ideal because they cool quickly and fill voids around irregularly shaped items. Folgen Sie dem 1:1 Regel (dry ice weight equals the frozen product weight) for two day transit, and increase by 25–50 % in summer or hot lanes.
Bakery or meal kits: Frozen meals and desserts often ship at –18 °C. Moderate amounts of dry ice (2–3 lb per day) with insulated liners maintain quality for up to 72 Std.. One bakery improved hold time by switching from 1 in to 1.75 in EPS and raising dry ice from 6 lb zu 8 lb, keeping pastries below –10 °C for 52 Std..
Electronics and pharmaceuticals: Use pack sheets to avoid direct contact between dry ice and sensitive equipment. Insert foam separators or corrugated boards and monitor humidity. You don’t want condensation in your instruments!
Wirklicher Fall: Eine Bäckerei Versand 6 lb of frozen pastries in summer switched to thicker insulation and added more dry ice. Infolge, core temperature stayed below –10 °C for 52 Std., Auftauen verhindern. This example underscores the importance of matching insulation and ice quantity to the route and season.
Wie viel Trockeneis brauchen Sie? Calculating the right amount
Start with simple ratios: A common baseline is a 1:1 mass ratio of dry ice to frozen product for a 48 hour shipment. For one day trips, half the payload weight is often sufficient; for three day journeys, plan for 1.5 times the payload weight. Adjust up by 25–50 % for hot weather or complex multi handoff lanes.
Rule of thumb formulas
Professionals often use formulas to predict how much dry ice to pack:
Simple time based estimate: Trockeneis (lb) ≈ (Transit time in hours ÷ 24) × Average consumption rate per day. Zum Beispiel, if your vaccines need 5 lb per day and transit lasts 36 Std., multiply (36 ÷ 24) × 5 = 7.5 lb and round up to 8 lb for safety.
Mass based rule: Trockeneis (kg) = [Produktmasse (kg) × 1.1 × Transittage] × 1.15. The multiplier accounts for a 10 % buffer for unforeseen delays and a 15 % Sicherheitsmarge. Versand 5 kg of steak for two days means you need roughly 12.7 kg Trockeneis.
Seasonal adjustments: Many shippers begin with equal weight of dry ice to payload and then add 0.15 for shoulder seasons or 0.35 for summer, subtracting 0.10 for thicker insulation.
Payload specific recommendations
Ultra cold vaccines and biologics: Use about 5–10 lb (2.3–4,5 kg) pro 24 Std.. Use more for mRNA or cell therapy products that require –70 °C conditions.
Seafood and meats: 1–2 lb (0.45–0.9 kg) per day for small shipments. Bulk loads may require double that amount.
Frozen meals and desserts: 2–3 lb (0.9–1.4 kg) per day.
General guideline: Half the payload weight for next day shipping, Gleiches Gewicht für zwei Tage, and one and a half times for three days.
| Payload weight (lb) | Dry ice for 24 H | Dry ice for 48 H | Dry ice for 72 H | Practical implication |
| 10 | 5 lb | 10 lb | 15 lb | Suitable for vaccines/samples on two day routes |
| 20 | 10 lb | 20 lb | 30 lb | Ideal for frozen foods or ice cream up to three days |
| 50 | 25 lb | 50 lb | 75 lb | Works for large meat or seafood shipments |
| 100 | 50 lb | 100 lb | 150 lb | Used for palletized cargo and industrial shipments |
Tips for accurate calculation
Pre freeze products: Chill your payload to at least –20 °C before packaging; this reduces the heat load and extends hold time.
Use data loggers: Place a temperature sensor inside the package and analyze the profile on test runs. Adjust the ice quantity accordingly.
Account for sublimation rates: Dry ice loses 3–8 % of its weight per day; pellet form can sublimate around 2 % per hour during flight. Add extra ice for warm or low pressure environments.
Adjust for container insulation: Thicker EPS or vacuum insulated panels reduce sublimation by lowering heat transfer. A container with a minimum R value of 4.6 hr·ft²·°F/BTU can hold –18 °C for 48 Std..
Wirklicher Fall: In a gene therapy shipment, combining blocks and pellets, pre conditioning the box, and filling voids with custom slices kept viral vectors below –65 °C for 72 Std.. Without careful sizing and preparation, the same load might have thawed or wasted dry ice.
Packing dry ice safely: Belüftung, Isolierung & Beschriftung
Safety starts with the container. Dry ice is a Class 9 hazardous material, and improper packaging can lead to injury or even aircraft incidents. Follow these guidelines:
Pre condition and insulate: Cool the container or cooler before adding dry ice to minimize thermal shock. Use double wall cartons with at least 30 mm of EPS insulation. For extra hold time, upgrade to vacuum insulated panels (VIPs), which cut sublimation rates drastically.
Position dry ice correctly: Placing blocks on top allows cold air to sink evenly through the shipment, while bottom placement creates a cold base. Surround sensitive items with foam or cardboard to prevent direct contact. For pack sheets, wrap them around the goods, leaving small vent gaps.
Hohlräume füllen: Empty space accelerates convection and ice loss. Use kraft paper, bubble wrap or additional slices to minimize air pockets.
Vent and label: Never seal a dry ice package airtight; verlassen 6 mm holes and avoid taping over vent ports. Mark packages “Dry Ice” or “Carbon Dioxide, Solide,” include the net weight and the identification number UN 1845. A 100 mm hazard diamond (Klasse 9) helps prevent ramp rejection.
Schutzausrüstung tragen: Isolierte Handschuhe, goggles and aprons protect against frostbite. Work in well ventilated areas to avoid CO₂ buildup. Never ingest dry ice or allow it to touch skin — contact can cause injury in under 30 Sekunden.
Record and monitor: Weigh and document the dry ice amount, attach a temperature logger, and log the data electronically. Modern carriers often require electronic entry of dry ice net weight as part of 2025 e audit processes.
Common mistakes & how to avoid them
Sealing dry ice in plastic bags: Gas will burst sealed bags. Always use breathable pouches or vented boxes.
Ignoring ventilation: A tightly sealed container can explode from CO₂ pressure. Leave vent holes and avoid closing them with tape.
Exceeding weight limits: IATA allows passengers to carry only 2.5 kg (5.5 lb) of dry ice without paperwork; commercial packages can contain up to 200 kg. Don’t overfill or you’ll need additional declarations.
Using generic boxes: Non insulated containers lead to rapid sublimation and thawing. Invest in purpose built dry ice containers or VIP shippers.
Neglecting PPE: Frostbite occurs quickly with bare hands. Provide gloves and face protection for everyone handling the ice.
Safety reminder: In 1998 a cargo plane taxiing in Brownsville, Texas experienced crew incapacitation after CO₂ from several dry ice packages built up in the cockpit. The National Transportation Safety Board traced the incident to inadequate ventilation and packaging. Proper venting and adherence to weight limits could have prevented the event.
Packaging elements and their impact
| Komponente | Empfehlung | Impact on hold time |
| Dämmstärke | ≥30 mm EPS or higher; R value ≥4.6 hr·ft²·°F/BTU | Reduces heat transfer and sublimation rate |
| Belüftung | 6 mm holes or self venting lids; never seal | Prevents pressure buildup, meets DOT/IATA rules |
| Etikettengröße | 100 mm-Klasse 9 hazard diamond | Ensures carrier acceptance and avoids delays |
| Secondary packaging | Use triple packaging for biological samples: primary leak proof container, secondary receptacle with absorbent material, strong outer box | Protects against leaks, meets UN 3373 / PI650 requirements |
| Net weight documentation | Record dry ice weight and include on airway bill | Simplifies compliance and e audits |
Navigating regulations: PUNKT, Iata & 2025 Einhaltung
Trockeneis wird als Klasse eingestuft 9 Gefahrgut, meaning special packaging, labeling and documentation are required. Here’s what you need to know:
Hazard classification and identifiers
Dry ice’s proper shipping name is “dry ice” or “carbon dioxide, solide" with the identification number Und 1845. Packages must bear a Klasse 9 hazard diamond and display the Nettogewicht Trockeneis. Hazard labels should be at least 100 MM Quadrat.
Weight limits and passenger allowances
Passenger airlines: Individuals may carry up to 2.5 kg (5.5 lb) of dry ice without filing a dangerous goods declaration. Exceeding this amount requires special paperwork and carrier approval.
Commercial shipments: Carriers typically allow up to 200 kg von Trockeneis pro Packung, though some cargo only aircraft permit 3,000 kg per pallet. USPS permits unlimited dry ice for surface transport if the package is vented, but air shipments are limited to 2.27 kg pro Paket.
Hazmat declaration: When dry ice is used solely to cool non dangerous goods, a hazardous materials declaration is generally not required; labeling and notation of net weight suffice.
Packaging and venting requirements
Regulations under 49 CFR173.217 (PUNKT) Und IATA -Packanweisung 954 mandate that packaging be designed to release CO₂ gas and prevent pressure buildup. Steel drums or sealed containers are prohibited because they can explode. Approved materials include fiberboard, plastic or metal boxes with venting ports and adequate insulation. When shipping infectious substances, follow triple packaging rules: a primary watertight vessel, a secondary leak proof package with absorbent material, and a strong outer box.
Documentation and e audits
Carriers like FedEx and UPS now require electronic entry of dry ice net weight and emergency phone numbers on airbills. Im März 2025, DOT PHMSA SP 15238 introduced a rule mandating that packaging vent CO₂, and IATA’s 66th Dangerous Goods Regulations set a new 3,000 kg pallet cap. Keeping digital records of your shipments helps ensure compliance and simplifies audits.
Dry ice vs gel packs vs phase change materials: choosing the right coolant
While dry ice provides ultra cold temperatures, other cooling agents may suit your needs better. Understanding their differences helps you choose wisely.
| Cooling method | Temperaturbereich | Dauer | Gefahrenklasse | Wiederverwendbarkeit | Am besten für |
| Trockeneis | –78,5 ° C. (Solid Co₂) | 48–72 h | Klasse 9 hazardous | Einmalgebrauch | Ultra cold shipments: Impfungen, Biologika, gefrorenes Fleisch |
| Gelpackungen | 0–10 ° C (water based) | 12–24 h | Non hazardous | Wiederverwendbar | Chilled foods, produzieren, some vaccines |
| Phasenwechselmaterialien (PCMs) | –20 °C or +2–8 °C | 24–96 h | Non hazardous | Wiederverwendbar | Products needing narrow temperature bands |
Which should you choose?
Verwenden Sie Trockeneis when your products must remain frozen or below –60 °C. Its extreme cold makes it indispensable for mRNA vaccines, gene therapies and premium ice cream.
Choose gel packs for refrigerated goods like meal kits, produce or pharmaceuticals that should stay between 0–10 °C. Gel packs are easier to handle and don’t require hazmat training.
Select PCMs when you need precise temperature control and sustainability. PCMs can be reused for 30+ cycles and avoid hazardous materials fees. They are ideal for biologics and shipments requiring 2–8 °C or –20 °C.
Hybridsysteme: Combine PCMs with 70 % dry ice to extend hold time and reduce weight, saving up to 18 % on coolant costs. This strategy also helps avoid hazmat surcharges.
2025 cold chain trends: Nachhaltigkeit, Technologie & market shifts
Trendübersicht
Demand for dry ice continues to climb at roughly 5 % per year, yet global CO₂ supply is increasing by only 0.5 %, creating shortages and price volatility. Spot prices can spike up to 300 % in peak seasons. Als Antwort, manufacturers are building localized pelletizing facilities and exploring bio based CO₂ sources. The market for reusable cold chain packaging — including insulated boxes, pallets and PCM packs — is expected to grow from USD 4.97 billion in 2025 to USD 9.13 billion by 2034 mit a 6.98 % CAGR. Sustainability demands, increased biologics shipments and booming food e commerce are driving this growth.
Neueste Fortschritte auf einen Blick
Self venting VIP lids: Engineers have developed vented lids that withstand three times the IATA pressure specification, improving safety while maintaining insulation.
On site pelletizers: Companies are investing in localized dry ice production to cut CO₂ shortages and reduce scope 3 emissions.
Machine learning dosing: AI models predict sublimation rates to within ±5 %, helping shippers optimize dry ice usage.
Recycelbare gepolsterte Versandtaschen: New R6.1 padded mailers keep contents at –15 °C for 48 hours and are curbside recyclable.
Reusable cold chain packaging: The reusable market is growing rapidly. Reusable insulated boxes and pallet shippers dominated 2024, while IoT enabled tracking containers are expected to grow fastest.
Nachhaltigkeit & circular economy: Companies are shifting to closed loop systems and biodegradable insulation materials such as bio PCMs, starch blends and wool liners. These innovations reduce waste and align with ESG goals.
Schlau & active packaging: IoT -Sensoren, NFC, RFID and Bluetooth Low Energy provide real time temperature, humidity and location tracking. Self refrigerated smart boxes like Ember Cube maintain precise temperatures for 72 hours and transmit live data.
Standardized pooling models: Shared reusable containers (Z.B., IFCO SmartCycle crates) gewinnen an Traktion, reducing logistics costs and enabling circular reuse.
Biodegradable insulation: Plant based foams such as ClimaCell and wool liners offer the same thermal performance as EPS but are compostable.
Multi temperature zone shippers: New designs allow different temperature requirements in a single container, useful for mixed loads of frozen and chilled goods.
Real time data & Blockchain: Blockchain enabled cold chain logs enhance traceability and compliance for vaccines and biologics.
Automation friendly reusables: With more warehouses adopting robotics, containers are becoming machine compatible, stackable and modular.
Markteinsichten
The global reusable cold chain packaging market is valued at USD 4.97 billion in 2025 and is projected to reach USD 9.13 billion by 2034, growing at a 6.98 % CAGR. Growth is fueled by sustainability initiatives, stricter regulations on single use plastics and increased demand for biologics and meal kits. North America leads adoption, but Asia Pacific is rapidly emerging. Plastik (HDPE/PP) containers dominate by material type, while composite/metal based containers are expected to grow fastest. IoT enabled tracking containers and PCM packs are the fastest growing add on features.
Häufig gestellte Fragen
Q1: How long does 5 lb of dry ice last in a pack sheet?
A five pound block or pack of dry ice typically lasts 30–36 Stunden in a 30 mm EPS container at 21 °C ambient temperature. Plan for an extra 20 % to buffer against unexpected delays.
Q2: Do I need a hazmat declaration for shipping dry ice?
If dry ice is used solely to cool non dangerous goods, no hazardous materials declaration is required. You must label the package with “Dry Ice” or “Carbon Dioxide, Solide,” list the net weight and apply a Class 9 Hazard -Etikett.
Q3: Wie soll ich übrig gebliebenes Trockeneis entsorgen??
Let leftover dry ice sublimate outdoors in a well ventilated area. Never place it in sinks or closed rooms, and keep it away from children and pets.
Q4: Can I switch to PCMs to avoid hazmat fees?
Ja - phase change materials (PCMs) at –22 °C or 2–8 °C can replace or supplement dry ice for goods that tolerate warmer temperatures. Always verify lane performance before switching.
Q5: Are dry ice containers and pack sheets reusable?
Rigid containers made from HDPE or EPS can often be reused if they remain clean and intact. Jedoch, Die dry ice itself is single use, as it sublimates completely. For sustainability, consider using reusable containers with PCM packs.
Zusammenfassung & Vorschläge
Dry ice containers and pack sheets are essential tools for ultra cold logistics. By understanding sublimation and choosing the right format, you can keep products frozen for 48–72 hours while preventing moisture damage. Calculating the correct ice weight using simple formulas and adjusting for transit time, insulation and weather avoids thawing and waste. Safe packing requires pre conditioning containers, Entlüftung, filling voids and labeling packages properly. Compliance with DOT and IATA regulations — such as weight limits, hazard labeling and triple packaging — protects you and your carriers. Comparing dry ice with gel packs and PCMs helps you pick the right refrigerant for your payload. Endlich, staying aware of 2025 trends — like reusable insulated boxes, IoT enabled smart packaging and sustainable materials — positions you ahead of market shifts.
Umsetzbare nächste Schritte
Assess your payload: Determine whether you need ultra cold (–78 ° C.), gekühlt (0–10 °C) or narrow band (–20 °C or 2–8 °C) conditions.
Select the right container and ice type: Choose blocks for long trips, pellets for rapid cooling or hybrid systems combining PCMs for efficiency.
Calculate dry ice requirements: Use the rule of thumb formulas provided to size your coolant. Always add a buffer for hot weather or multi handoff lanes.
Pack safely: Pre condition the container, position dry ice strategically, fill voids and ensure ventilation. Label packages clearly and wear PPE.
Bleib konform: Keep up with DOT and IATA regulations, note weight limits and document net dry ice weight on the airway bill. Use digital logs to simplify audits and training.
Entdecken Sie Innovationen: Evaluate reusable insulated boxes, IoT monitoring and biodegradable insulations to future proof your cold chain. Consider integrating AI driven calculators and interactive tools on your website to help customers plan shipments.
Über Tempk
Tempk is an innovative cold chain solutions provider specializing in insulated packaging, dry ice containers, gel packs and PCM systems. Wir invest heavily in research and development, offering products made from eco friendly materials such as high density EPS, vacuum insulated panels and bio based foams. Our quality assurance program meets international standards, and our Sedex certification underscores our commitment to ethical and sustainable manufacturing. With tailored solutions for food delivery, pharmaceuticals and industrial applications, Tempk helps you keep shipments fresh while reducing waste and costs.
Aufruf zum Handeln: Bereit, Ihre kalte Kette zu optimieren? Contact Tempk’s experts for a free cold chain consultation or try our interactive dry ice calculator to size your next shipment. Your products — and your customers — deserve the best.
