Dry Ice Small Pack: Elegir, Tamaño & Envolver 2025

If you need a dry ice small pack that keeps shipments frozen and compliant, here’s the playbook. Pick a vent‑friendly pouch, size the refrigerant correctly, and apply UN1845/Class 9 labels for air. Passenger travel is limited to 2.5 kg, and USPS air mail caps dry ice at 5 lb per piece. Use the sizing estimator below to plan mass before a lane test.

When a dry ice small pack beats gel/PCM for true frozen integrity on parcel lanes
How much dry ice small pack you need for 24–72 hours across mild, warm, and hot routes
How to pack and label under PI 954 (UN1845) so carriers accept your box the first time
Safety and 2025 updates that matter for air, suelo, and passenger travel

What is a dry ice small pack—and when should you use it?

A dry ice small pack is a compact, vented configuration that holds dry ice inside an insulated shipper to keep payloads ≤ −18 °C for 24–72 hours. Use it when the product must remain fully frozen end‑to‑end and your carrier accepts UN1845. Avoid sealed pouches; dry ice must vent as it sublimes to CO₂ gas.

In plain terms: gel packs hover near 0 °C; many PCMs hold +3/+5/+7/+17 °C—great for chilled lanes, not for hard‑frozen outcomes. Dry ice sits near −78.5 °C, giving you deep‑cold headroom through handoffs and door‑opens. Choose gel/PCM only when a chilled band is acceptable and you want to skip dangerous‑goods handling.

Dry ice small pack vs. gel/PCM for common parcel goals

Bottom line: pick the tool that matches your temperature goal and acceptance constraints.

Use case (goal)	Best pick	Typical duration	What this means for you
Helado, carne (stay frozen)	Dry ice small pack	24–72 h	Requires venting + UN1845/Class 9 by air; robust frozen integrity.
2–8 °C pharma or meal kits	+5 °C PCM or gel	12–96 h	Tight, non‑frozen band; simpler handling and labeling.
Heat‑sensitive confection (+17 ° C)	+17 ° C PCM	24–72 h	Avoids bloom; validate in hot lanes before scale‑up.

Practical tips for you

Respiradero, don’t seal: never heat‑seal dry ice in plastic; use vent‑friendly pouches or paper bags.
Condición previa: freeze product ≤ −18 °C and pre‑chill the shipper to extend hold time.
Distribute mass: split dry ice into multiple smaller packs and place some on top to reduce hot spots.

Real‑world snapshot: A bakery shipped croissants with two vented paper bags (~6 lb total) inside an EPS shipper. With UN1845/Class 9 labels, the box held below −15 °C for 36 hours and passed acceptance on the first attempt.

How much dry ice small pack do you need for 24–72 hours?

Fast rule‑of‑thumb: plan 5–10 lb (2.3–4.5 kg) per 24 hours in a parcel‑size cooler. Use the high end for hot lanes or frequent door‑opens, and add a buffer day for delays.

Physics‑first estimator (more precise): dry ice absorbs about 571 kJ/kg as it sublimes. Multiply your hourly heat leak by transit hours, then divide by 571, and add a 10–20% buffer. It’s a reliable starting point before lane testing.

Suggested starting ranges (tune after your first lane test):

Duración	Mild (≤ 22 °C)	Warm (23–30 °C)	Caliente (≥ 31 °C)	Why this matters
~24 h	2–3 kg	3–5 kg	5–6 kg	Split into ≥ 2 packs; add top coverage.
~48 h	4–6 kg	6–8 kg	8–11 kg	Add side + top packs for stability.
~72 h	6–8 kg	9–12 kg	12–15 kg	Consider larger box or better insulation.

Colocación & box size (practical details)

Box volume: 10–20 L shippers are common for a dry ice small pack. Larger boxes increase heat load.
Layering: bottom bag → payload → top bag; add side bags for > 48 h. Fill voids to slow convection.
Hybrid trick: a thin −20 °C PCM touching the product can smooth door‑opens while keeping dry ice mass modest.

How to pack and label a dry ice small pack in 2025?

Core compliance (aire): use packaging that permits CO₂ release, marca “Carbon dioxide, solid” or “Dry ice” + UN1845 + Kg neto, and apply a Class 9 label on the same face. Use the IATA PI 954 acceptance checklist at tender. Sealed plastic bags are prohibited.

Step‑by‑step SOP you can paste into your manual:

Prepare vent‑friendly pouches (paper dry‑ice bags or sleeves). Do no seal dry ice airtight.
Layer smartly: bottom pack → payload → top pack; add sides for longer lanes.
Vent the outer shipper: close firmly but avoid airtight seals; leave a gas path.
Label clearly: UN1845 proper name + Kg neto + Class 9 label (≥ 100 mm).
Book correctly: some operators ask for net kg at booking to manage aircraft limits.

Aire, suelo, USPS, and passenger nuances

Passenger travel: ≤ 2.5 kg (5.5 lb) per passenger/package with airline approval; the package must vent and be marked.
USPS air mail: ≤ 5 lb dry ice per mailpiece under Packaging Instruction 9A; venting and markings required.
Carrier notes: FedEx reiterates no sealed plastic and cites a 200 kg/package ceiling (well above small‑pack needs). UPS/express networks mirror PI 954 venting and marking rules.

Dry ice small pack safety: simple rules that prevent incidents

Short list that saves headaches: ventilate the room, wear insulated gloves and eye protection, and never trap CO₂ in sealed layers. Train staff to handle small pieces with tongs and to avoid packing in enclosed vehicles or cold rooms with poor airflow.

Quick safety checklist

Vent every layer: pouch → inner liner (open) → outer shipper (ventilado).
PPE: cryo‑compatible gloves, safety glasses minimum.
No airtight seals: never heat‑seal dry ice in plastic; leave a gas path.
Staging areas: keep out of confined spaces; CO₂ can pool low and displace oxygen.

2025 dry ice small pack updates and trends

What’s new: 2025 operator job aids emphasize envasado ventilado, clear UN1845 marks, and providing net kg at booking. Expect acceptance audits that verify PI 954 checklists even for very small parcels. Retail dry ice availability remains strong through major grocers for last‑minute top‑ups.

Latest developments at a glance

Stronger documentation: IATA’s 66th‑edition addendum tightened booking data requests for dry ice.
Safer packouts: carrier pages stress no sealed plastic and adequate venting.
Chilled alternatives mature: +3/+5/+7/+17 °C PCMs now cover many non‑frozen lanes without DG handling.

Market insight: shippers increasingly reserve a dry ice small pack for true frozen lanes and shift 2–8 °C work to PCMs to reduce labels, surcharges, and exception risk—all while maintaining product integrity.

Frequently asked questions

How much dry ice small pack for 48 hours?
Plan 10–20 lb depending on insulation and ambient heat; add a buffer day for delays or hot hubs.

What labels go on a dry ice small pack by air?
Apply UN1845 nombre de envío adecuado, Kg neto, y un Class 9 etiqueta (≥ 100 mm) on the same face; follow the PI 954 acceptance checklist.

Can I seal dry ice in a plastic bag?
No. Sealed plastic is prohibited. Packaging must allow CO₂ to escape safely.

What’s the passenger allowance?
Arriba a 2.5 kg (5.5 lb) per passenger/package with airline approval; package must vent and be marked.

Does USPS allow dry ice?
Sí. Air mail pieces are limited to ≤ 5 lb and must meet Packaging Instruction 9A.

Resumen & recommendations

Control de llave: a dry ice small pack delivers deep‑frozen control when gel/PCM fall short. Success comes from envasado ventilado, UN1845 + Kg neto + Class 9 marks, y right‑sizing with the 571 kJ/kg estimator before lane validation. Follow PI 954 and operator variations to avoid rejections.

Siguientes pasos (action plan):

Map transit time and ambient peaks.
Comenzar con 5–10 lb per 24 h and split across multiple packs.
Print labels to your carrier’s 2025 character‑height guidance.
Run a lane test with a logger; adjust ± 10–20%.
CTA: Share your lane, payload mass, and box size—we’ll return a validated small‑pack SOP.

Acerca de Tempk

We’re a cold‑chain packaging team focused on practical validation. We combine quick thermal estimates with real route tests to tune dry ice small pack mass, mark‑and‑label templates, and booking checklists. Customers choose us for fast SOPs y fewer acceptance issues—especially on hot lanes and multi‑stop routes.

Ready to design your small‑pack? Contact a Tempk specialist for a lane‑specific spec and SOP.