UN dry ice alternative dry ice pack sheet is transforming the way you manage temperature sensitive shipments. Instead of relying solely on traditional dry ice, innovative sheets encapsulate CO₂ snow or phase change material in flexible cells, delivering sub zero temperatures without hazardous residue. This matters because global dry ice consumption is growing about 5% annually while CO₂ supply grows only 0.5%thermosafe.com, causing shortages and price spikes. Pack sheets and other alternatives offer longer cooling, Designs réutilisables, et moins d'obstacles réglementaires. In this guide you’ll learn how to choose the right solution, use it safely, and stay ahead of 2025 tendances.
Understanding the technology: What exactly is a dry ice alternative dry ice pack sheet and how does it differ from traditional dry ice or gel packs?
Selection criteria: When should you choose a pack sheet versus other alternatives, and how do temperature range, duration and regulations affect your decision?
Safe usage tips: How do you prepare, pack and handle dry ice alternative sheets to maximise hold time and minimise risk?
Future trends: What market and technology developments in 2025 will influence your cold chain strategy, from bio based CO₂ to IoT enabled packaging?
FAQ: Answers to common questions about safety, reusability and cost.
What Is a Dry Ice Alternative Dry Ice Pack Sheet?
A dry ice alternative dry ice pack sheet combines the ultra cold performance of traditional dry ice with the convenience of a reusable sheet. Each sheet contains multiple sealed cells filled with either CO₂ snow or engineered phase change material. Quand il est gelé, the sheet provides temperatures between −20 °C and −60 °C for 36–72 hours. Unlike loose pellets that sublimate rapidly and leave residue, pack sheets encase the refrigerant to minimise CO₂ gas release and liquid runoff, making them easier and safer to handle. They are classified as non hazardous so you avoid many hazardous materials rules.
Dry ice pack sheets were developed to address the mismatch between rising dry ice demand and limited CO₂ supplythermosafe.com. By using less CO₂ and combining it with phase change material, they extend cooling duration and reduce emissions. Reusability means the same sheet can be hydrated, frozen and used multiple times, providing both cost and sustainability benefits. Because the refrigerant stays contained, pack sheets also reduce frostbite risk during packing and unpacking.
How Do Pack Sheets Compare to PCM Gel Packs?
Matériel à changement de phase (PCM) gel packs absorb and release heat at specific temperatures. They typically maintain 2 °C à 8 °C ou −20 °C ranges, making them suitable for vaccines, biologics and clinical samples. Contrairement à la glace sèche, PCMs are reusable and non hazardous, which simplifies compliance and reduces disposal. Gel packs melt more slowly and uniformly than water based ice, making them ideal for overnight or 48 hour shipmentstrans.info.
Dry ice pack sheets, en revanche, deliver much colder temperatures (−20 °C to −60 °C) for 36–72 hours. They bridge the gap between gel packs and traditional dry ice, offering extended sub zero performance without the regulatory burdens of loose CO₂. When shipping mixed loads—such as frozen goods alongside refrigerated items—you can layer PCM packs above products and place dry ice pack sheets below to create separate thermal zones. This hybrid method reduces total CO₂ consumption while ensuring each product stays within its required range.
| Solution de refroidissement | Typical Temperature Range | Durée | Impact pratique |
| Dry ice pack sheet | −20 °C to −60 °C | 36–72 h | Réutilisable, minimal CO₂ release, ideal for frozen foods and biologics; manipulation plus sûre |
| PCM gel pack | 2 °C à 8 °C or −20 °C | 24–96 h | Maintains precise refrigerated ranges; non hazardous and reusable |
| Glace sèche traditionnelle | < −70 °C | 24–48 h | Delivers ultra cold conditions for deep frozen samples but requires hazardous materials labeling |
| Water based gel pack | 0 °C to −20 °C | 24–48 h | Inexpensive, melts uniformly but offers shorter durationtrans.info |
| Eutectic plate | +2 °C à +8 °C | 48–96 h | Rigid reusable plates for stable refrigerator temperatures; used in closed loop systems |
Practical Tips for Using Pack Sheets
Hydrate and freeze properly: Most dry ice alternative sheets must be hydrated and frozen solid before use. Follow manufacturer instructions and freeze at least 24 hours to ensure all cells are solid.
Pre condition containers: Pre chill insulated boxes or pallet shippers before loading. This reduces thermal shock and slows sublimationthermosafe.com.
Superposer stratégiquement: Place dry ice pack sheets above the payload so cold air sinks and envelops the productthermosafe.com. Use PCM or gel packs for upper layers if shipping items with different temperature requirements.
Éliminer les vides: Fill empty gaps with insulating material or cut pack sheets to fit; void spaces create warm pockets where sublimation acceleratesthermosafe.com.
Allow ventilation: Ensure containers have vent holes to release CO₂ and prevent pressure build up. This is especially important when combining pack sheets with pellets or blocksthermosafe.com.
Étude de cas: A biotech manufacturer switched from standard gel packs to reusable PCM containers for 2–8 °C payloads. After ten shipments, they saw no temperature excursions and a 40 % cost reduction, thanks to fewer product losses and lower waste disposal fees. In another scenario, food shippers replaced loose dry ice with pack sheets and improved insulation, extending transit time from 36 heures pour 60 hours and cutting CO₂ usage by 20 %.
Why Switch to Dry Ice Alternative Pack Sheets in 2025?
Supply constraints and cost volatility make dry ice alternatives attractive. Dry ice consumption has been climbing around 5 % per year, while CO₂ supply grows only about 0.5 %thermosafe.com. This imbalance triggers shortages and price surges of up to 300 % during crunch periodsthermosafe.com. Replacing or supplementing dry ice with pack sheets reduces dependence on a scarce resource and provides more predictable budgets.
Sustainability is reshaping cold chain operations. Most industrial CO₂ is fossil derived, and food and pharma companies face pressure to lower their carbon footprint. Manufacturers are investing in bioethanol and direct air capture to produce greener CO₂thermosafe.com. Using reusable pack sheets and PCM packs reduces waste and emissions, aligning with environmental goals. Reusable designs also avoid the disposal fees associated with single use pellets.
Regulatory compliance becomes simpler. Traditional dry ice shipments fall under IATA, DOT and UN hazardous materials rules, requiring specialized labeling, documentation and training. Dry ice alternative sheets are typically classified as non hazardous. This simplifies air freight, reduces paperwork and speeds customs clearance, especially when shipping internationally.
Longer hold times improve product quality. Dry ice pack sheets maintain sub zero temperatures for up to 72 hours—longer than many loose pellet shipments. When combined with improved insulation and PCMs, they can extend hold times by 25 % while reducing dry ice consumption by 18 %【150738139107786†L382-L429】. For e commerce food deliveries or long haul pharma shipments, longer duration reduces spoilage and customer complaints.
How to Use Dry Ice Alternative Pack Sheets Safely and Efficiently?
Shipping with pack sheets requires careful preparation. Follow these guidelines to maximise performance:
Plan the temperature profile. Determine the required temperature range for your product. Par exemple, vaccines need 2 ° C - 8 ° C stability while frozen seafood may require −20 °C. Choose pack sheets or PCM packs accordingly.
Pre condition your container. Chill insulated shippers before loading. Pre conditioning lowers the initial thermal shock and slows the rate of sublimationthermosafe.com. Utiliser, high performance insulation and tight seals; generic boxes allow too much heat ingressthermosafe.com.
Prepare the sheets. Hydrate reusable pack sheets if necessary and freeze them solid. For PCM packs, ensure they have completed a full freeze cycle. For hybrid shipments, freeze both pack types at their respective temperatures (Par exemple, freeze PCM packs at −20 °C and pack sheets at −30 °C).
Couper correctement. Place the heaviest refrigerant (pack sheets or dry ice pellets) au-dessus de the payload so cold air sinks. If using both PCMs and pack sheets, separate them with a buffer (Par exemple, bubble wrap or corrugated board) to prevent direct contactthermosafe.com. Ensure vents are unobstructed to avoid dangerous CO₂ accumulation.
Fill voids and insulate. Use insulation such as crumpled paper or foam inserts to eliminate air pockets that accelerate warmingthermosafe.com. Tailor pack sheet sizes or cut along perforations to fit snugly around products without leaving empty spaces.
Seal and label packages. Close containers securely to maintain insulation. Label shipments to indicate the presence of CO₂ or PCMs; although pack sheets are non hazardous, carriers appreciate clear handling instructions. Always provide documentation if using any dry ice pellets in combination.
Surveiller la température. Incorporate data loggers to track internal conditions. IoT enabled devices provide real time alerts and support regulatory compliance for pharmaceuticals【150738139107786†L382-L429】.
Dry Ice Alternatives vs Dry Ice Pack Sheets: Which One to Choose?
Selecting the right cooling method depends on four factors:
Target temperature range: Use PCM packs for 2 ° C - 8 ° C ou −20 °C produits. Choose dry ice pack sheets for –20 °C to –60 °C goods such as frozen desserts, cell therapy shipments or seafood. Reserve traditional dry ice for ultra cold needs below –70 °C, like CRISPR materials and cryogenic samples.
Shipment duration: PCM packs perform well for 24–96 hours, depending on configuration. Pack sheets offer 36–72 heures of sub zero cooling. Traditional dry ice lasts 24–48 heures but can be extended with better insulationthermosafe.com. For shipments longer than four days, consider hybrid systems or mechanical refrigeration.【150738139107786†L382-L429】
Regulatory complexity: If avoiding hazardous materials paperwork is important, select pack sheets or PCM packs. Use traditional dry ice only if you’re comfortable with IATA/DOT rules.
Budget and sustainability goals: PCM solutions involve higher up front costs but deliver long term savings via reuse and reduced waste. Dry ice sheets strike a balance—more affordable than high end PCMs yet reusable and less wasteful than pellets. Traditional dry ice is inexpensive per shipment but involves recurring costs for each replenishment.
User Centric Recommendations
Exportation de fruits de mer: Combine dry ice pack sheets with high performance insulation to maintain –25 ° C pour jusqu'à 60 heures, reducing spoilage and eliminating hazmat fees.
Biopharma shipments: Use PCM packs for refrigerated biologics and place a dry ice sheet layer for temperature critical vials. Incorporate data loggers to meet 21 Partie CFR 11 exigences.
E commerce meal kits: Opt for reusable pack sheets paired with biodegradable gel packs. This hybrid approach extends shelf life and supports brand sustainability commitments.
Exemple du monde réel: A gene therapy firm used validated dry ice shippers with phase change barriers and training protocols, enabling deep freeze shipments that cleared customs without HAZMAT issues. Another company adopted local bio ethanol CO₂ capture to produce dry ice, demonstrating how sustainability can enhance supply securitythermosafe.com.
2025 Trends and Innovations in Dry Ice Alternatives
Aperçu de la tendance
Le global dry ice market was valued at USD 1.54 milliards en 2024 and is expected to reach USD 2.73 milliards 2032, a compound annual growth rate of 7.4 %thermosafe.com. Entre-temps, le dry ice alternative PCM market is booming—estimated at USD 1.2 milliards en 2024 and projected to hit USD 3.7 milliards 2033 avec un 13.2 % TCAC. Demand is fuelled by pharmaceuticals, biotechnologie, e commerce and sustainability pressures. Here are key 2025 tendances:
Derniers développements
Systèmes de refroidissement hybrides: Shippers are layering dry ice pack sheets with PCM gel packs and improved insulation to extend hold times by 25 % while reducing dry ice consumption by 18 %【150738139107786†L382-L429】.
Localized CO₂ production: Manufacturers are investing in local production hubs and exploring on site CO₂ capture to secure supply and reduce transport lossesthermosafe.com. Bioethanol plants capture high purity CO₂ released during fermentation and redirect it into dry ice productionthermosafe.com, creating a circular and lower carbon pathway.
Emballage intelligent: IoT sensors and real time monitoring devices are being integrated into cold chain containers to track temperature and CO₂ levels【150738139107786†L382-L429】. Data insights enable dynamic routing and proactive interventions.
Regulatory shifts: Stricter environmental regulations and carbon taxes are pushing companies toward non hazardous refrigerants and sustainable packaging. Many airlines impose weight and quantity limits on dry ice to reduce CO₂ emissions【150738139107786†L382-L429】.
Regional growth: North America currently accounts for more than 37 % of the PCM market due to mature cold chain infrastructure and sustainability mandates, while Asia Pacific is growing at 15.8 % annually driven by healthcare and e commerce demand.
Insistance au marché
Regulatory and consumer pressures are accelerating adoption of recyclable materials and reusable cold packstrans.info. Food and meat processors are moving toward thinner slices and pellets for rapid cooling, while blocks remain the choice for bulk transportthermosafe.com. Pharmaceutical shippers are testing barrier technologies that slow CO₂ gas release and adopting real time monitoring to ensure compliancethermosafe.com. Industrial contractors are locking in long term supply contracts and investing in local pelletizing capacity to reduce reliance on distant suppliersthermosafe.com. Finalement, the cold chain industry in 2025 is both expanding and evolving: supply shortages, sustainability pressures and new alternatives are pushing companies to rethink how they produce, source and use dry icethermosafe.com.
Questions fréquemment posées
What is a dry ice alternative dry ice pack sheet?
A dry ice alternative dry ice pack sheet is a reusable sheet containing CO₂ snow or phase change material. Il maintient −20 °C to −60 °C for 36–72 hours without hazardous materials classification, providing a safer and longer lasting alternative to loose dry ice pellets.
How long does a pack sheet last compared to dry ice?
Pack sheets typically last 36–72 heures, whereas traditional dry ice pellets or blocks offer 24–48 heures Selon l'isolation. When combined with improved insulation, hybrid systems can extend hold time by 25 %【150738139107786†L382-L429】.
Are dry ice alternative pack sheets safe for food shipments?
Oui. Because the CO₂ is contained within sealed cells, there is minimal risk of direct product contact or frostbite. They are classified as non hazardous and leave no liquid residue, making them ideal for perishable foods.
Can I reuse dry ice alternative pack sheets?
Many pack sheets are designed for reuse. Après utilisation, let any remaining CO₂ sublimate in a well ventilated area, rehydrate if required, refreeze and inspect for damage. Following proper care routines can extend service life.
When should I still use traditional dry ice?
Traditional dry ice is indispensable for temperatures below –70 °C, such as cryogenic samples or ultra cold vaccines. For these applications, consider combining pellets with pack sheets and PCMs to reduce total dry ice consumption.
Résumé & Recommandations
Choosing the right cooling method is crucial for product safety, cost control and sustainability. Dry ice alternative dry ice pack sheets deliver extended sub zero performance without hazardous materials rules, making them ideal for many frozen shipments. Pairing them with Packs de gel PCM allows mixed temperature zones and reduces CO₂ dependence. Pre conditioning containers, layering correctly and eliminating voids are key to maximising hold time. The dry ice market will continue to face supply constraints and sustainability pressuresthermosafe.com, so adopting reusable pack sheets and smart packaging today positions your business for success in 2025 et au-delà.
Étapes suivantes
Assess your current shipments. Identify which products require ultra cold, frozen or refrigerated conditions and evaluate how long they spend in transit.
Trial pack sheets and PCM packs. Start with small pilot shipments. Use data loggers to compare temperature stability and total cost against your existing dry ice set up.
Améliorer l'isolation. Invest in high performance containers and pre chill them before packing. This simple step can reduce sublimation loss by up to 8 % per daythermosafe.com.
Educate your team. Train staff on proper handling, superposition, and ventilation. Provide clear checklists and PPE to prevent injuries.
Consult Tempk experts. Our specialists can help you design a hybrid solution tailored to your payloads, shipping duration and compliance requirements.
À propos du tempk
Tempk is a leading innovator in cold chain packaging solutions. We design and manufacture reusable dry ice alternative pack sheets, phase change gel packs and high performance insulated containers. Our products are validated for pharmaceutical, biotechnologie, food and logistics applications and help reduce carbon footprints by using recyclable materials and bio based CO₂ where possiblethermosafe.com. With global production hubs, we ensure reliable supply and consistent quality. Nous work closely with clients to optimise temperature control, meet regulatory standards and lower total cost of ownership.
Étapes suivantes
Interested in implementing dry ice alternative pack sheets? Contact our team for a personalised consultation or request a trial kit. Together we can enhance your cold chain performance and sustainability.
