Keeping vaccines, biologics and frozen foods at the right temperature can mean the difference between a life saving delivery and a spoiled shipment. Flexible dry ice pack sheets son livianos, moldable packs filled with synthetic gel and dry ice that rapidly freeze to around –78.5 °C. Una vez hidratado, they expand into three centimetre thick pads and provide up to seven times longer cooling than traditional ice. These sheets can be cut to shape and tucked around irregular products, making them ideal for next generation cold chain logistics. In this guide you’ll learn what they are, how to size them correctly, best practices for safe handling and the latest 2025 innovations shaping ultra cold logistics.
Definition and structure: what makes a flexible dry ice pack sheet different from a gel pack or conventional dry ice.
Sizing and packing: rule of thumb formulas for how much dry ice to use per shipment based on weight and duration.
Comparisons: when to choose flexible dry ice sheets versus gel packs or PCM solutions, including temperature ranges and regulatory differences.
Safety and regulations: handling precautions, ventilación, and disposal guidelines.
2025 tendencias: market dynamics, sustainability initiatives and emerging technologies reshaping the use of flexible dry ice sheets.
What Are Flexible Dry Ice Pack Sheets and How Do They Work?
Flexible dry ice pack sheets are dehydrated gel packs that combine an absorbent sodium polyacrylate copolymer with perforated plastic and non woven textile layers. Each sheet is typically about 29×20 cm and 2 mm thick before activation and weighs about 40 gramo. When hydrated in warm water for about 15 minutos, the cells absorb water and swell to form a reusable pad weighing roughly 900 gramo. The sheet shrinks in length and breadth as the thickness increases to around 3 centímetro. Because the polymer traps water within sealed cells, the sheet becomes flexible when frozen and can be cut to fit different container shapes. Una vez congelado, the gel core freezes into solid CO₂ ice, sublimating from solid to gas at –78.5 °C. This ultra cold sublimation provides continuous, residue free cooling without melting water.
Anatomy of a Flexible Dry Ice Sheet
The typical sheet consists of four layers: two perforated plastic layers on the outside and two non woven textile layers on the inside. These encapsulate the sodium polyacrylate polymer that retains water during hydration. The perforations allow water to enter when the sheet is soaked, and the hydrated polymer expands until it fills each cell. Because the cells are sealed, they don’t leak even when frozen or thawed. After repeated use the cells may dehydrate; simply rehydrating them restores full thickness.
El dry ice effect occurs during freezing. When the hydrated sheet is placed in a freezer, the water in the cells freezes around dry ice pellets or created carbon dioxide in the gel. As the solid CO₂ sublimates, it absorbs a large amount of heat, maintaining the surrounding temperature far below freezing without leaving any liquid residue. This property makes flexible sheets ideal for shipping frozen seafood, biologics and high value perishables that cannot tolerate warming.
Benefits Over Traditional Ice
| Característica | Flexible dry ice sheet | Traditional ice pack | Por qué te importa |
| Starting weight | ~40 g before hydration, ~900 g after | A menudo >500 gramo | Lower shipping weight reduces costs. |
| Thickness after activation | ~3 cm | Varía (often thicker) | Slim profile fits tight spaces. |
| Cooling temperature | –78.5 °C sublimation for ultra cold** | 0 °C melting point | Maintains deep freeze conditions without water damage. |
| Residuo | Sublimates to CO₂ gas | Leaves meltwater | Eliminates leaks and soggy packaging. |
| Reutilizabilidad | Cells can be rehydrated for multiple uses | Usually single use | Reduces waste and cost over time. |
Consejos y consejos prácticos
Cut to size: The perforated cells mean you can cut the sheet to wrap around irregularly shaped products without losing material. Always seal cut edges with tape to prevent the gel from escaping.
Hydrate correctly: Soak the sheet in warm water for about 15 minutos, gently scrunching to ensure all cells fill completely. Over hydrating can make cells prone to puncture; remove the sheet when it indents under light pressure.
Pre freeze: For optimum performance, freeze the hydrated sheet at least 24 hours before packing. This allows the dry ice to form uniformly and reduces sublimation during transit.
Wrap sensitive items: For goods sensitive to extremely low temperatures, place a layer of insulation or gel packs between the dry ice sheet and the product. This prevents over freezing while still leveraging the cold air from sublimation.
Estudio de caso: A seafood exporter needed to ship fresh tuna steaks from California to Asia. By cutting flexible dry ice sheets to fit the contours of each insulated box, the company kept the fish frozen for 60 hours in transit. The lightweight sheets reduced overall shipping weight by 20 %, saving on air freight costs, and there was no meltwater to damage packaging.
How to Size and Pack Flexible Dry Ice Sheets for Shipping?
Proper sizing is critical for maintaining target temperatures and avoiding waste. An easy rule of thumb is to base the amount of dry ice on the weight of the payload and the desired transit time. Para envíos al día siguiente, pack roughly half the weight of your product in dry ice sheets, mientras equal weight will keep products frozen for up to 48 horas. One and a half times the product weight may be necessary for 72 hour journeys. The dry ice should be placed above the payload so that cold air sinks and envelops it.
Rule of Thumb for Dry Ice Quantity
| Payload weight (libras) | hielo seco (libras) para <12 horas | Dry ice for 24–48 hrs | Dry ice for 48–72 hrs | Practical implication |
| 10 | 5 | 10 | 15 | Use a half sheet for overnight; double for two days; triple for longer trips. |
| 20 | 10 | 20 | 30 | Double the payload weight ensures frozen conditions up to 48 horas. |
| 40 | 15 | 25 | 40 | Para envíos más grandes, layering sheets on the top and bottom helps extend hold time. |
These numbers are guidelines. Actual requirements depend on external temperatures, insulation quality and starting temperature of the goods. To minimize sublimation:
Pre condition containers: Chill insulated boxes before loading. A warm container accelerates sublimation.
Minimize voids: Fill empty space with insulating filler or padding. Void spaces allow warm air pockets, increasing sublimation.
Vent properly: Use boxes designed with venting to allow CO₂ gas to escape. Sealed containers can explode due to pressure build up.
Layer the sheets: Place dry ice sheets on top of the payload, not beneath it. Fregaderos de aire frío, so top layering maintains uniform temperatures.
Packing Tips for Different Scenarios
Small medical shipments (2–5 lb payload): Use one sheet cut to size (half the payload weight) for overnight deliveries. For biologics requiring 48 horas, use one full sheet above and a half sheet below.
Meal kits and frozen foods (10–15 lb): For two day transit, use two full sheets (equal weight). Sandwich the goods with one sheet on top and one bottom to maximize cold retention.
Biotech samples (20 LB+): For 72 hour shipments, use 1.5–2 times the payload weight spread across multiple sheets. Combine with phase change materials or gel packs to reduce supercooling and extend duration.
Real world example: A biotechnology company shipping 25 lb of cell culture kits across the U.S. used 30 lb of flexible dry ice sheets placed on top of the payload. They pre chilled containers and filled voids with recyclable foam, logro 60 hours of sub zero conditions with only 5 % sublimation loss.
Comparing Flexible Dry Ice Sheets with Gel Packs and PCM Solutions
Choosing the right refrigerant depends on temperature targets, regulatory constraints and shipment duration. Materiales de cambio de fase (PCM) absorb and release heat at set points (p.ej., 2–8 °C o –20 °C) and maintain narrow ranges for pharmaceuticals and vaccines. PCMs are reusable and classified as non hazardous, which reduces shipping restrictions. hielo seco, por otro lado, sublimates at –78.5 °C, providing ultra cold conditions ideal for frozen biologics and enzymes. Sin embargo, dry ice requires hazardous materials labeling, venting and adherence to IATA, DOT and UN regulations.
Temperature Range and Use Cases
| Packaging type | Typical temperature range | Best use cases | Key considerations |
| Flexible dry ice sheet | –78.5 °C during sublimation | Frozen cells, clinical trial specimens, cryo preserved tissues | Ultra cold; must handle hazardous CO₂ gas; single use but can rehydrate gel for multiple cycles. |
| paquetes de gel (water based) | 2–8 ° C (melting point around 0 °C) | Productos frescos, kits de comida, pharmaceuticals that must not freeze | No peligroso; leaves meltwater; limited duration compared with dry ice. |
| Paquetes de PCM | 2–8 °C or –20 °C engineered setpoints | Vacunas, biológicos, reactivos | Reutilizable; stable temperature band; high upfront cost but lower long term waste. |
Durabilidad, Cost and Sustainability
Gel and PCM packs are generally durable and reusable; they are encased in flexible pouches or rigid panels that resist punctures. Flexible dry ice sheets are re usable for multiple hydration cycles but require new dry ice for each use. PCMs have higher upfront investment but deliver cost savings over multiple shipments and generate less waste. Dry ice sheets have lower initial cost but incur recurring expenses for replenishment and disposal. In sustainability terms, PCMs reduce CO₂ emissions and hazardous waste because they avoid sublimation of carbon dioxide.
Decision Making Framework
When choosing between flexible dry ice sheets, gel packs or PCMs, considerar:
Target temperature: Use dry ice for ultra cold (< –70°C) shipments such as cell therapy or CRISPR samples. Choose PCMs or gel packs for 2–8 °C or –20 °C products like vaccines, meal kits and fresh produce.
Shipment duration: PCMs support shipments up to around 72 horas. Para duraciones más largas, dry ice or hybrid systems are needed.
Regulatory complexity: If you wish to simplify compliance, select PCMs (no peligroso). Use dry ice only if you are comfortable handling hazardous materials and can provide proper labeling.
Budget and sustainability goals: Reusable PCM systems have higher upfront costs but lower lifetime expenses and waste. Dry ice sheets have low cost per use but require frequent replenishment and produce CO₂ emissions.
Consejo: Hybrid solutions combine PCM packs with flexible dry ice sheets. A PCM layer buffers the payload at 2–8 °C while a dry ice sheet on top extends ultra cold life. This reduces total dry ice required and minimizes supercooling risks.
Seguridad, Handling and Regulations
Dry ice is extremely cold and sublimates to carbon dioxide gas, creating both frostbite and asphyxiation hazards. Follow these best practices:
Use protective gear: Always wear loose fitting, thermally insulated gloves and eye protection when handling dry ice sheets. Use tongs instead of bare hands to prevent frostbite.
Ventilación: Store and transport dry ice in well ventilated areas. CO₂ gas buildup in sealed containers or confined spaces can cause asphyxiation. Do not store dry ice in airtight boxes; ensure there is an outlet for gas release.
Enclose and label: Enclose dry ice sheets within an outer wrapping or bag to avoid direct contact with food. Provide clear instructions to recipients. Packages exceeding 5.5 lb (2.5 kilos) of dry ice require compliance with US 49 CFR and IATA hazardous materials regulations. Paquetes fríos, por el contrario, have no regulatory requirements.
Desecho: Allow unused dry ice to sublimate outdoors or in a well ventilated area. Never dispose of dry ice in sinks or toilets because the extreme cold can damage plumbing. Rehydrate gel sheets for reuse; the polymer itself is typically non hazardous.
Sustainability Considerations
The dry ice market faces supply constraints because CO₂ consumption is growing faster than production capacity. Consumption has been rising by roughly 5 % por año, while CO₂ supply has grown only 0.5 % anualmente, causing periodic shortages and price spikes up to 300 %. A pesar de esto, global demand continues to increase: the dry ice market was valued at Dólar estadounidense 1.54 mil millones en 2024 and is projected to reach Dólar estadounidense 2.73 mil millones por 2032, a compound annual growth rate of 7.4 %. To combat shortages and reduce carbon footprints, manufacturers are building more localized production hubs and exploring on site CO₂ capture, including using by product CO₂ from bioethanol plants. Shippers are also mixing dry ice with PCMs and improving insulation to stretch each pound of dry ice further.
One promising sustainability pathway is bio based CO₂. Bioethanol plants capture CO₂ released during fermentation and purify it for dry ice production. This creates a circular supply chain and reduces reliance on fossil based CO₂. Sin embargo, geopolitical and trade pressures can threaten local CO₂ supply; Por ejemplo, UK producers warn of supply disruptions due to tariff changes. Such issues highlight the need for diversified supply and resilient sourcing strategies.
2025 Trends Shaping Flexible Dry Ice Sheets and Cold Chain Logistics
Market Dynamics and Innovation
The dry ice industry is evolving rapidly in response to supply constraints, rising demand and sustainability pressures. Las tendencias clave incluyen:
Localized production and on site CO₂ capture: Companies are building regional production hubs and capturing CO₂ from industrial processes to ensure steady supply.
Sistemas de enfriamiento híbrido: Shippers are layering flexible dry ice sheets with PCMs or gel packs to reduce total dry ice usage, manage temperature ranges and extend shipment duration.
Improved insulation and packaging design: Innovations such as vacuum panels, curbside recyclable materials and form fitting containers reduce sublimation losses by 3–8 % per day and allow for smaller dry ice quantities.
Monitoreo en tiempo real: Internet of Things (IoT) sensors integrated into dry ice containers provide real time data on temperature, humidity and CO₂ levels, allowing proactive intervention if anomalies occur. This supports compliance with 21 Parte CFR 11 for pharmaceutical shipments.
Reusable PCM shippers: En el sector farmacéutico, reusable PCM shippers are gaining traction for less temperature critical medicines, reducing reliance on dry ice while still meeting regulatory requirements.
Format optimization: Dry ice format (bloques, bandear, slices) dramatically affects performance. Large blocks sublimate slowly for longer trips, while pellets provide rapid cooling for short hauls. Thin flexible sheets strike a balance by fitting snugly around payloads and minimizing void space.
AI driven logistics planning: Sophisticated software models evaluate variables such as route length, ambient temperature and insulation quality to recommend the optimal combination of flexible dry ice sheets, PCMs and container types. This minimizes waste and ensures compliance with sustainability targets.
Market Outlook for 2025–2030
The combination of supply constraints and rising demand means prices are likely to remain volatile. Sin embargo, innovation is easing pressure. Hybrid solutions and better insulation reduce consumption per shipment, while bio based CO₂ sources expand capacity. The growth of e commerce for frozen foods and direct to patient pharmaceuticals will further drive demand for flexible dry ice sheets.
Across sectors, the focus will be on resilience and sustainability. Food and meat processors are investing in better insulated boxes and optimizing dry ice formats to reduce sublimation. Pharma and biotech companies are balancing ultra cold needs with supercooling risks, often using barrier technologies and reusable PCM systems. Industrial users are locking in long term contracts and investing in local pelletizing capacity. For all stakeholders, flexible dry ice sheets remain a critical tool but will increasingly be complemented by PCMs, IoT monitoring and smarter packaging.
Preguntas frecuentes (Preguntas frecuentes)
Q1: How long do flexible dry ice pack sheets last?
When properly hydrated, frozen and packed, flexible dry ice sheets can maintain ultra cold temperatures for 24 a 72 horas, depending on quantity and external conditions. Use half the payload weight for overnight shipments and up to 1.5× for 72 hour deliveries.
Q2: Can flexible dry ice sheets be re used?
Sí. After the dry ice has sublimated, the gel cells can be rehydrated and refrozen for multiple cycles. Sin embargo, you’ll need a fresh supply of dry ice or a freezer to recharge the sheets.
Q3: How do flexible dry ice sheets compare to gel packs?
Dry ice sheets maintain temperatures around –78.5 °C and don’t produce meltwater, whereas gel packs maintain about 0 °C and may leak. Gel packs are ideal for goods that must not freeze, while dry ice sheets are best for ultra cold shipments.
Q4: Are flexible dry ice sheets safe for air transport?
Sí, but there are strict limits. Non medical shipments containing more than 5.5 lb (2.5 kilos) of dry ice require hazardous materials labeling and must comply with 49 CFR y IATA regulaciones. Packages below this threshold still need ventilation and clear labeling.
Q5: What is the environmental impact of using flexible dry ice sheets?
Traditional dry ice relies on industrial CO₂, which can contribute to greenhouse gas emissions when produced from fossil sources. The market is shifting toward bio based CO₂ capture and local production hubs to reduce emissions. Using hybrid systems with PCMs and improved insulation also reduces total dry ice consumption, lowering the carbon footprint.
Resumen y recomendaciones
Flexible dry ice pack sheets offer a versatile, high performance solution for ultra cold shipping. Their lightweight, cut to size design, extreme cooling capacity and ability to rehydrate make them a superior alternative to traditional ice packs. To get the most from these sheets:
Follow sizing rules: Pack 0.5–1.5× the payload weight in dry ice sheets depending on duration.
Optimize packing: Pre condition containers, minimize voids, vent gas and layer sheets on top of the payload.
Assess alternatives: For 2–8 °C shipments, gel or PCM packs may suffice; consider hybrid systems for longer durations or mixed loads.
Prioritize safety and compliance: Use equipo de protección, ensure ventilation and label packages when shipping more than 2.5 kg de hielo seco.
Embrace sustainability: Support suppliers using bio based CO₂ and invest in reusable PCM systems and improved insulation.
By applying these practices, you’ll reduce costs, protect product integrity and align your cold chain operations with 2025’s regulatory and sustainability expectations.
Acerca de Tempk
Templ is a leader in cold chain packaging solutions. We design and manufacture flexible dry ice sheets, phase change materials and insulated containers tailored to pharmaceuticals, biotecnología, food and industrial customers. Our products combine validated thermal performance con eco conscious materials, reducing waste and ensuring compliance with global transport regulations.
Our Advantages
Tailored design: We offer customizable sheet sizes and container solutions to meet specific payload dimensions and transit times.
Expert support: Our engineers provide sizing guidance, regulatory compliance assistance and real time monitoring integration to optimize your cold chain workflows.
Sostenibilidad: We partner with suppliers who capture CO₂ from bioethanol and industrial processes, and we continuously invest in recyclable materials and hybrid PCM/dry ice innovations.
Llamado a la acción
Ready to revolutionize your cold chain operations? Tempk de contacto to discuss how flexible dry ice pack sheets and hybrid solutions can safeguard your products, reduce costs and meet 2025 sustainability goals. Our team will help you choose the right packaging, calculate required dry ice and implement monitoring tools for total peace of mind.
