Shipping perishable goods, biologics or gourmet meals requires more than just ice. UN customized dry ice pack, designed around your cargo’s size and hold time, keeps products at 78.5 °C without leaving moisture. In this guide you’ll learn why tailored packs matter, how to choose the right configuration and what 2025 innovations mean for you. À la fin, you’ll know exactly how to optimise temperature control while reducing costs and environmental impact.
Why are customized dry ice packs superior to standard packs? Understand the science of sublimation and why –78.5 °C cooling gives your products longer protection.
How do you select the right pack size, cell count and materials? Explore customization options from 5–20 cells and learn how cutting packs improves fit and savings.
What cost and sustainability benefits can customized packs bring? See how reusable bags and smart materials cut waste and reduce carbon impact.
How to meet regulations and safety requirements? Compare real dry ice vs gel or PCM packs and learn venting and labelling rules for 2025 expéditions.
What are the latest market trends and innovations for 2025? Discover how IoT sensors, hybrid cooling and circular economy models are transforming the cold chain.
Why choose a customized dry ice pack for shipping?
Réponse directe: A customized dry ice pack gives you ultra cold temperatures for longer. Dry ice sublimates at –78.5 °C and leaves no moisture, so your goods stay dry and cold. When packs are tailored to your box size and hold time, there’s less empty space and more efficient cooling. Standard packs can waste space, over cool or under perform. Customized packs maintain temperature for up to 72 heures, reducing spoilage and meeting regulatory requirements.
Explication élargie
Imagine sending a lifesaving vaccine or gourmet seafood across the country. If the ice pack is too small, it warms up mid journey. If it’s too large, it adds unnecessary weight and cost. Customized dry ice packs solve this by matching the cell count, dimensions and weight to your specific cargo. Packs can have 5–20 cells and be cut to the required length. This flexibility prevents over packing and allows precise temperature control. Des études montrent que dry ice maintains a stable –78.5 °C environment without condensation, meaning sensitive products arrive unspoiled. En comparaison, gel packs only reach around 0 °C and cannot achieve the extreme cold needed for biologics or frozen desserts.
Additional Details: Performance versus Alternatives
Gel or water packs are ideal for chilled foods (2–8 ° C) because they are safe, reusable and affordable, but they cannot provide ultra low temperatures. Dry ice packs are essential for 24–72 hour shipments requiring deep freeze, such as cellular therapies, ice cream or cryogenic research. Contrairement aux packs de gel, dry ice sublimates directly into CO₂ gas and leaves no liquid residue, so there’s no risk of soggy packaging.
| Option de refroidissement | Typical Temperature Range | Durée | Avantage pratique |
| Paquet de glace sec (personnalisé) | –78,5 ° C (ultra cold) | 24–72 heures | Keeps biologics and frozen goods at ultra low temperatures without moisture. Best for pharmaceuticals and gourmet frozen foods. |
| Gel/water pack | autour 0 °C | 12–36 heures | Réutilisable, safe and cost effective for meal kits and fresh produce. Cannot achieve deep freeze. |
| Matériau à changement de phase (PCM) paquet | Pre set temperatures (Par exemple, 0 °C, –20 ° C) | 24–48 heures | Provides narrow temperature bands; used for chilled or sub zero shipments when dry ice is restricted. |
Practical Tips and Advice
Right shipment: Use dry ice packs for products needing –20 °C to –78.5 °C. For chilled foods, combine hydration sheets and PCM bricks.
Balance weight and duration: A rule of thumb is 5–10 lb (2.3–4,5 kg) de glace sèche par 24 heures of transit. Adjust based on insulation quality and outside temperature.
Safety first: Always allow proper ventilation; dry ice gives off CO₂ gas. Use UN1845 labels and follow carrier requirements.
Reuse and disposal: Many high quality dry ice sheets are reusable and can endure 50+ cycles. For single use packs, follow local recycling guidelines.
Real world example: A biotech firm shipping cell therapy products across continents adopted customized dry ice packs with integrated sensors. By matching cell count and adding thermal insulation, they extended hold time from 36 heures pour 60 hours and reduced product loss by 90 %. IoT monitoring alerted them to any temperature excursions, ensuring regulatory compliance and patient safety.
How to customize dry ice packs: tailles, cells and materials?
Réponse directe: Customization involves choosing the right cell count, material and packaging. Dry ice packs typically come in sheets of 5–20 cells, and you can cut them to the precise length needed. Selecting the correct insulation (Par exemple, kraft paper bags, Mylar, Mousse de polystyrène) and outer packaging ensures maximum performance. You can also add branding or logos on bags and choose reusable or disposable formats.
Explication élargie
The flexibility of dry ice sheets allows you to match pack size to your box or product. Par exemple, un 10 cell sheet might be trimmed to 7 cells for a narrow container, reducing weight and preventing over cooling. Cutting packs not only improves fit but also saves costs and extends cooling duration. Manufacturers offer various insulation materials: kraft paper bags provide strength and insulate while being recyclable and biodegradable; Mylar or foil bags reflect heat and reduce sublimation; Styrofoam liners add structural support and high R value for long transit.
Customisation also includes the outer bag or pillow. Companies like Relocalize allow full customization of weight, size and packaging format and support private labelling with custom logos. Great American Packaging offers heavy duty dry ice bags with high strength, strong seals and extreme-cold tolerance. They can print up to 10 couleurs and match your brand palette. Wisconsin Converting’s kraft paper dry ice bags are recyclable and biodegradable, meeting sustainability goals. These options allow you to align packaging with your brand identity while maintaining performance.
Choosing the right insulation and packaging
When selecting materials, Considérez ce qui suit:
Kraft paper bags: Provide natural insulation and are eco friendly. They add structural support and are recyclable.
Mylar or reflective foil: Minimizes heat gain through radiation and reduces sublimation. Ideal for long distances.
Reinforced plastic bags: Offer puncture resistance and moisture barriers; suitable for heavy or sharp products.
Foam or Styrofoam inserts: Increase the R value of packaging, extending cooling duration but add bulk. Use them for shipments exceeding 48 heures.
| Customization Aspect | Options | Why it Matters to You |
| Cell count | 5–20 cells per sheet | Cutting the sheet to fit your container reduces waste and optimizes cooling; more cells mean longer duration. |
| Matériel d'isolation | Kraft paper, Mylar, mousse | Determines how long the dry ice lasts and how strong the packaging is. Eco friendly options boost sustainability goals. |
| Outer bag features | Heavy duty film, strong seals, custom printing | Prevents breakage and leaks; printing supports branding and regulatory information. |
| Reusable vs disposable | Reusable sheets (50+ cycles) vs one time packs | Reusable packs reduce cost per use and environmental impact. Disposable packs offer convenience and hygiene. |
Practical Tips and Advice
Start with a trial: Order sample sheets from multiple suppliers and perform thermal validation tests. Evaluate hold time and fit before full scale adoption.
Combine insulation layers: For shipments over 48 heures, combine a customized dry ice sheet with PCM bricks or hydration packs to create a hybrid cooling system.
Étiqueter clairement: Use printed bags to display handling instructions and your brand, which helps customers and carriers follow best practices.
Restez durable: Opt for recyclable kraft paper or bags produced with renewable CO₂ to reduce your carbon footprint.
Actual Case: A meal kit company switched from standard dry ice blocks to custom 7 cell sheets placed in kraft paper bags. By adjusting cell count and adding foam liners, they maintained perfect –18 °C temperatures for 48 heures, reduced CO₂ consumption by 20 % and gained positive customer feedback on the improved unboxing experience.
How does customization improve cost efficiency and sustainability?
Réponse directe: Tailored dry ice packs reduce waste, optimise load density and enhance reusability, resulting in lower shipping costs and environmental impact. Since dry ice sublimates directly to CO₂, there’s no leftover water to dispose of, and using only the required number of cells cuts consumption. Reusable bags and packs reduce the need for single use plastics, while eco friendly materials like kraft paper support circular economy principles.
Explication élargie
Cost efficiency comes from matching the dry ice quantity to the shipment. Overfilling a box with dry ice not only wastes CO₂ but also increases shipping weight, leading to higher freight costs. Cutting packs to size allows you to use only what’s needed, with cost savings of 10–25 % according to industry surveys. Extended hold times mean fewer reships and less product loss. Sustainability is enhanced when suppliers utilise renewable CO₂ sources; par exemple, dry ice produced from bioethanol fermentation captures CO₂ that would otherwise be vented. Kraft bags and recyclable film reduce waste, and reusable sheets can be refrozen 50+ fois.
Quantifying savings and environmental benefits
Consider the following example to understand the impact of customization:
| Métrique | Standard Pack | Customized Pack (7 cellules) | Avantage |
| Dry ice used per shipment | 10 kg | 7.5 kg | 25 % reduction in CO₂ consumption and shipping weight. |
| Durée de refroidissement | ~36 h | 48 h | Fewer re icing interventions during transit. |
| Packaging waste | Single use plastic bag | Reusable kraft bag | Reduced plastic waste and easier recycling. |
| Cost per shipment | $15 | $12 | Savings on refrigerant and freight costs. |
Practical Tips and Advice
Measure your hold times: Use data loggers to verify how long your customized packs maintain the desired temperature; adjust cell counts accordingly.
Choose renewable CO₂ sources: Ask suppliers about bio-based dry ice; capturing CO₂ from bioethanol fermentation creates a lower carbon product.
Promote reusability: Provide return instructions for customers or partners to send back reusable packs. Partner with manufacturers who offer recycling programs.
Monitor supply chain: Diversify CO₂ supply to avoid shortages and price spikes; localizing production reduces transport emissions.
Industry insight: The dry ice market faces supply constraints; consumption grows around 5 % annuellement, while CO₂ supply only increases 0.5 %, causing price volatility. Customization helps mitigate this by using dry ice more efficiently and integrating alternative refrigerants like phase change materials..
What safety and regulatory considerations apply to customized dry ice packs?
Réponse directe: La glace sèche est classée comme un matières dangereuses (UN1845) because it emits CO₂ gas. Regulations require proper labelling, venting and protective gear. When customizing packs, ensure that bags have vent holes or use packaging with pressure relief valves. Always follow carrier guidelines and shipping company instructions, Surtout pour les expéditions aériennes.
Explication élargie
Because dry ice sublimates directly into gas, closed containers can build up pressure. Customized packs must be placed in emballage ventilé or combined with vented coolers to allow CO₂ to escape. For shipments by air, L'Association internationale des transports aériens (Iata) limits the amount of dry ice and requires hazard labels and declarations. Gel and PCM packs, en revanche, are non hazardous and require fewer paperwork but cannot reach ultra cold temperatures.
Practical guidelines for safe use
To safely handle customized dry ice packs:
Utiliser un équipement de protection: Wear insulated gloves and goggles when handling dry ice sheets to avoid frostbite and eye injury.
Provide ventilation: Do not seal packs in airtight containers. Use insulated boxes with vents or pressure release valves.
Comply with labels: Mark shipments with the UN1845 label and include the total weight of dry ice. Add hazard statements such as “Dry Ice – DO NOT TOUCH” on custom-printed bags.
Train staff and customers: Provide handling instructions in packaging and train employees on emergency procedures.
Additional Considerations
For pharmaceuticals and biologics, regulators may require validation studies showing that your custom dry ice solution maintains temperature for the required time. Document your thermal testing and integrate monitoring sensors that log data for audits. Always check country-specific rules; Par exemple, some destinations restrict dry ice quantity or require specific documentation.
Exemple de cas: A healthcare logistics provider experienced a near-miss when an improperly vented custom dry ice shipment expanded and cracked its insulated box. After redesigning their packaging to include vents and training drivers, they prevented future incidents and remained compliant with IATA and OSHA regulations.
When should you choose dry ice, PCM or gel packs?
Réponse directe: Use dry ice when products must stay below –20 °C or remain frozen solid (Par exemple, vaccins, glace). Choisir PCM or gel packs for chilled shipments (2–8 ° C), for foods like meal kits or produce. Hybrid approaches that combine dry ice and PCMs offer extended hold time and more stable temperature profiles.
Explication élargie
Glace sèche: Contains solid CO₂ that sublimates at –78.5 °C, producing extremely low temperatures and long hold times. It’s ideal for shipments requiring deep freeze for 24–72 hours and where water condensation is unacceptable, such as cell therapies, cryogenic research and gourmet desserts.
Packs PCM: Employ phase change materials engineered to melt and freeze at specific temperatures. They are available for 0 °C, –20 ° C, and other ranges. PCMs are safer and often reusable. Cependant, they are heavier and cannot reach the ultra cold range of dry ice.
Gel or water packs: Filled with frozen water or gel; they provide near freezing temperatures and are widely used in meal kits and produce shipping. They are non hazardous and can be reused many times.
H3: Deciding factors
To decide which refrigerant suits your shipment:
Temperature requirement: If products must stay below –20 °C, choose dry ice. Pour 0 ° C - 8 ° C, gel or PCM packs suffice.
Duration of shipment: Longer transit times (>48 heures) may require dry ice or hybrid systems combining dry ice and PCM bricks.
Safety and regulations: Dry ice requires hazmat labelling. If you want to avoid additional paperwork, select gel or PCM packs.
Durabilité: PCMs and gel packs are reusable and considered eco friendly; dry ice sublimates but requires energy to produce.
| Scénario | Recommended Solution | Raison |
| Vaccine or cell therapy shipment (–50 °C to –70 °C) | Customized dry ice pack | Provides required ultra cold temperature and long hold time; labelled for hazmat. |
| Meal kit requiring chilled temperature (2–8 ° C) | Gel or PCM pack | Non hazardous, reusable and cost effective. |
| Gourmet ice cream delivery across country (–20 ° C) | Glace sèche + PCM hybrid | Prolonge le temps de maintien, balances cost and weight. |
| Electronics or cosmetics requiring 10–15 °C | PCM pack with proper melt point | Maintains moderate temperatures without hazardous materials. |
Practical Tips and Advice
Always consult carriers about restrictions. Par exemple, airline carriers may limit dry ice weight to 2.5 kg par forfait.
Utiliser bûcherons de données to monitor temperature and adjust your refrigerant strategy accordingly.
Considérer seasonal variations: in summer or warm climates, allocate extra dry ice or add PCMs; in winter, reduce refrigerant to avoid freezing chilled products.
Real life example: A gourmet ice cream brand initially shipped orders using only gel packs, resulting in melted pints and unhappy customers. After switching to a hybrid system—custom dry ice packs layered with PCM bricks—the company maintained products at –20 °C for 48 heures, reduced refunds and boosted customer satisfaction.
How to implement and monitor custom dry ice pack usage?
Réponse directe: Effective implementation requires thermal validation, proper training and real time monitoring. Start with pilot shipments to determine hold times and adjust cell counts. Use IoT sensors to track temperature and humidity in real time, and adopt standard operating procedures (Sops) to ensure consistent preparation and handling.
Explication élargie
Proper use of customized dry ice packs involves more than placing them in a box. You should conduct thermal qualification tests for each product and packaging combination. This includes using data loggers or IoT sensors placed alongside the product to record temperature throughout transit. Le 2025 trend of integrating smart monitoring with packaging allows you to detect temperature deviations immediately. Once validated, develop SOPs for staff on how to flex, activate and arrange the dry ice sheets. Automated packing systems, which are increasingly common, reduce human error.
Steps for Successful Implementation
Assess shipment requirements: Determine the temperature range and duration needed for each product. Consider seasonal variations and transit routes.
Select and customize packs: Choose the correct cell count and material based on the product and shipping box. Order samples and cut sheets to fit.
Conduct thermal testing: Place data loggers inside test shipments with the selected refrigerant and packaging. Simulate worst case temperatures and adjust cell counts or insulation accordingly.
Document procedures: Create SOPs detailing how to handle, flex, activate and arrange the packs. Include safety instructions and labelling guidelines.
Train staff: Educate warehouse and fulfillment teams on proper preparation and hazard awareness. Use checklists to ensure compliance.
Monitor in real time: Implement IoT sensors that transmit temperature, humidity and location data. Integrate with your logistics platform to receive alerts when conditions deviate.
Review and improve: After each shipment, review data logs and customer feedback. Adjust your strategy to optimize performance and cost.
Additional Considerations
Automation and robotics are emerging in cold chain packaging. Automated systems can weigh, cut and place customized dry ice sheets precisely, reducing labour costs and variability. When selecting an IoT solution, ensure sensors are calibrated for ultra cold conditions and have sufficient battery life for your shipments.
Exemple: A medical device company implemented a structured rollout: they first tested various cell counts in a controlled lab, then ran pilot shipments with IoT sensors. By automating pack placement and training staff, they improved packaging consistency. Real time monitoring allowed them to intervene in case of delays, resulting in 99 % on time delivery and minimal temperature excursions.
2025 trends and innovations in customized dry ice packs
Aperçu de la tendance
The cold chain industry is evolving rapidly. Smart monitoring systems integrate IoT sensors into packaging, providing real time temperature and humidity data. Systèmes de refroidissement hybrides combine dry ice and PCMs to stabilise temperature and enhance energy efficiency. Automation in packing and handling reduces human error and increases throughput. Matériaux durables such as biodegradable films and recyclable kraft paper are becoming standard, and advanced PCM formulations extend the range and duration of packs. Integrated sensors within dry ice sheets transmit data to logistics platforms, allowing proactive interventions. Circular economy models encourage refurbishment and recycling of thermal materials. Demand for next day dry ice pack sheets is projected to grow 20 % annually through 2026.
Insistance au marché
Le global cold chain packaging market is forecast to reach US$27.1 billion in 2025 and could expand to US$104.7 billion by 2035, at a CAGR of 15.8 %. Growth is driven by the increasing trade of perishable goods and vaccines, strict regulatory requirements and the rise of e commerce. Refrigerant market value for cold chain packaging refrigerants is estimated at US$1.72 billion in 2025, avec de la glace sèche, gel packs and PCMs used to maintain temperature-sensitive products. Demand for dry ice is rising in pharmaceuticals and biologics, while e commerce expansion and grocery delivery platforms further drive the need for customised refrigerant solutions. Le dry ice market itself was valued at US$1.54 billion in 2024 and is projected to reach US$2.73 billion by 2032, but supply constraints and CO₂ shortages could affect pricing.
Latest advancements: En un coup d'œil
Capteurs intelligents: IoT enabled dry ice sheets monitor temperature and humidity in real time, enabling proactive responses.
Refroidissement hybride: Combining dry ice with PCMs smooths temperature fluctuations and reduces total dry ice required.
Automation & robotique: Machines cut and place dry ice sheets with precision, improving throughput and reducing human error.
Matériaux durables: Biodegradable films, recyclable kraft paper and renewable CO₂ sources minimize environmental impact.
Circular economy: Take back and refurbish programs reduce waste and cost.
Croissance du marché: Demand for next day dry ice pack sheets is rising by 20 % per year through 2026. Cold chain packaging value could exceed US$104.7 billion by 2035.
Market and consumer insights
In the food and beverage sector, consumers expect fresher products with minimal additives. Meal kit services rely on personalized cold packs to ensure safe deliveries. The pharmaceutical industry is seeing double digit growth in biologics and vaccines, requiring ultra cold shipping solutions. Regulations are tightening, encouraging companies to adopt eco friendly packaging and transparency. The rise of online grocery services and global trade accelerates demand for robust cold chain infrastructure. Entre-temps, supply constraints for CO₂ and pressure for low carbon solutions push companies to invest in renewable sources and hybrid systems.
Questions fréquemment posées
Q1: How long does a customized dry ice pack last?
Most customized dry ice packs maintain ultra cold temperatures for 24–72 heures, depending on the number of cells, insulation and ambient conditions. Adding more cells or using hybrid systems can extend hold time.
Q2: Can I reuse customized dry ice packs?
Oui. Many dry ice sheets are reusable and can be refrozen for 50+ cycles. Always check manufacturer instructions and inspect for damage before reuse.
Q3: Is dry ice environmentally friendly compared to gel packs?
Dry ice sublimates into CO₂ gas and leaves no liquid waste. While production is energy intensive, sourcing CO₂ from bio based processes like bioethanol fermentation reduces carbon footprint. Gel packs are reusable and considered eco conscious.
Q4: How many cells or sheets should I use for my product?
Determine the required temperature and duration, then start with 5–10 lb (2.3–4,5 kg) de glace sèche par 24 heures. Cut sheets to match your container dimensions and test with data loggers to refine cell counts.
Q5: Do custom dry ice packs require special handling or documentation?
Oui. Dry ice is a hazardous material (UN1845) requiring proper labelling and ventilation. Provide handling instructions on packaging and follow carrier guidelines. PCM and gel packs are non hazardous.
Q6: How do I dispose of or recycle used dry ice packs?
Allow remaining dry ice to sublimate in a well ventilated area. Dispose of or recycle the bag according to local regulations. Many manufacturers offer recycling programs; consider returning reusable packs to the supplier.
Summary and Next Steps
Principaux à retenir: Customized dry ice packs provide ultra cold temperatures (–78,5 ° C) for extended durations and leave no moisture. Tailoring cell count, size and materials yields cost savings, better fit and sustainability benefits. Hybrid cooling systems and IoT sensors are transforming cold chain logistics, with market growth projected to exceed US$104 billion by 2035. Supply constraints and environmental pressures make efficient use of CO₂ more important than ever.
Conseils exploitables: Start by assessing your product’s temperature and duration needs. Order sample packs with varied cell counts and run thermal tests. Develop SOPs for handling and labelling, and train your team. Invest in IoT sensors for real time monitoring. Choose suppliers who offer recyclable bags and renewable CO₂ sources. Enfin, integrate hybrid systems with PCMs to maximise efficiency and prepare for the future of cold chain shipping.
À propos du tempk
Tempk is a cold chain solutions provider specialising in dry ice packs, gel packs and insulated packaging. Nous design our products to maintain ultra low temperatures while prioritising safety and sustainability. Our customisable dry ice sheets and bags are engineered with high quality insulation materials, strong seals and extreme cold tolerance. We offer private labelling, 10 colour printing options and eco friendly kraft packaging. Our commitment to innovation includes integrating IoT sensors, adopting renewable CO₂ sources and participating in recycling programmes.
Appel à l'action: Ready to optimise your cold chain shipments? Reach out to Tempk’s specialists for a custom assessment. We’ll help you choose the right dry ice pack configuration, implement smart monitoring and achieve cost effective, sustainable shipping solutions.
