Dry ice shipping keeps frozen goods safe without melting, but only when you pack and label it correctly. Dans 2025, the baseline still holds: dry ice is –78.5 °C and typically sublimates 5–10 lb per 24 hours. If you plan the right container, ventilation, and weight, you prevent pressure build‑up and costly spoilage. This guide shows how to pack dry ice for shipping step by step, with simple rules you can apply today.
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How to pack dry ice for shipping with a proven three‑layer method
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How to size dry ice weight using quick rules and a table
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Quoi Et 1845 marking and safe venting mean in practice
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When to combine dry ice vs gel packs in one shipment
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2025 trends that cut cost and risk in dry ice shipping
How do you pack dry ice for shipping, step by step?
Use a three‑layer method and always allow gas to vent. Start with frozen goods, add dry ice above and around them, and keep the outer box loosely sealed so CO₂ can escape. This prevents pressure build‑up and keeps temperatures stable for 24–72 hours. Keep dry ice shipping labels visible on one side and note the net dry‑ice weight in kilograms for compliance.
Pourquoi ça marche: Cold air sinks. Placing bricks or pellets on top creates a steady “cold shower.” A loose seal lets gas out, avoiding ruptures. For most parcels, plan 5–10 lb per day and add a 24‑hour buffer. If contents are warm at pack‑out, dry ice consumption rises fast. In pharma or seafood lanes, use an insulated inner and sturdy outer to protect both product and handlers.
Which packaging performs best for dry ice shipping?
Use an insulated liner inside a strong outer box. Expanded polystyrene (PSE) or vacuum panels slow sublimation; a corrugated outer adds crush strength. Use cardboard separators so dry ice never touches delicate goods.
| Layered Pack | What to Use | Why It Matters | What It Means for You |
|---|---|---|---|
| Inner (produit) | Leak‑resistant poly bag | Contains spills; not airtight | Fewer returns and cleaner audits |
| Middle (isolation) | EPS liner or VIP | Extends hold time | Smaller dry‑ice loads, lower cost |
| Outer (expéditeur) | Double‑wall corrugated | Impact + label area | Survives hubs and handoffs |
Practical tips and quick wins
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Frozen first: Pre‑chill to –20 °C or lower to save 20–30% dry ice use.
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Mind the voids: Fill gaps with kraft paper (breathable) to stabilize loads.
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Never airtight: Leave a vent path; avoid sealed plastics that trap CO₂.
Real‑world result: A vaccine kit that moved to a vented EPS‑in‑box design held –20 °C for 48 hours with 15% less dry ice, and arrived without temperature excursions.
How much dry ice do you need for dry ice shipping?
Match dry ice to transit time and payload, then add a buffer. As a rule, plan ~0.5× payload for overnight, 1× for 48 hours, et 1.5× for 72 hours. Add more for hot routes or thin insulation. This keeps dry ice shipping resilient to delays.
Details that matter: Ambient heat, insulation density, and product start‑temp drive consumption. In summer or multi‑stop routes, add an extra day of dry ice. Distribute bricks top/side; consider a small bottom layer in heavy boxes to even the chill.
Suggested dry ice weights (test and adjust)
| Payload (kg) | 24 H (kg) | 48 H (kg) | 72 H (kg) | Ce que cela signifie pour vous |
|---|---|---|---|---|
| 5 | 5 | 10 | 15 | Small boxes stay frozen up to 3 jours |
| 10 | 8 | 10 | 15 | Equal weight works for 48 h lanes |
| 20 | 12 | 20 | 30 | Add bottom layer for balance |
| 30 | 15 | 30 | 45 | Use separators to avoid freeze burn |
| 50 | 25 | 50 | 75 | Reinforce outer box; label clearly |
Calculator you can use (simple rule)
Conseil: Pour air freight or customs‑heavy lanes, set heat_factor = 1.3 to cover delays.
What labels and documents does dry ice shipping require?
Marque, secouer, and declare. Use the proper shipping name «Dioxyde de carbone, Solide", Et 1845, and the net dry‑ice weight (kg) on the same side of the box. Keep packaging ventilé; never hermetically seal inner bags. Follow current IATA/air‑carrier variations and domestic rules (Par exemple, 49 CFR) pour dry ice shipping.
In plain words: Labels warn handlers; venting prevents pressure. Baggage limits are strict, while cargo shipments follow operator rules and packing instructions. Train staff on CO₂ hazard basics and PPE. Include handling notes for recipients so leftover dry ice sublimates in a ventilated area.
Quick compliance checklist
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Marking present: Et 1845 + «Dioxyde de glace sèche / carbone, Solide" + poids net
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Vented packaging: No airtight seals on any layer
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Docs ready: Air waybill states dry‑ice weight; shipper/consignee info visible
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Trained team: Gloves, tongs, eye protection; CO₂ exposure awareness
When should you combine dry ice and gel packs in one box?
Use dual‑zone packing when some items must not freeze. Dry ice keeps frozen goods solid; packs de gel protect items that need 0–4 °C. Separate zones with cardboard or foam so gel‑protected items don’t over‑freeze during dry ice shipping.
Why it helps: Gel packs slow sublimation and create a “soft chill” layer. This is ideal for meal kits, mixed biologics, or seafood. Test your layout before scaling—added weight changes freight class and handling.
Layout that prevents over‑freezing
| Zone | Réfrigérant | Placement | Meaning for you |
|---|---|---|---|
| Frozen items | Dry ice bricks | Haut + côtés | Rock‑solid proteins or reagents |
| Tampon | Foam/cardboard | Between zones | Stops freeze creep |
| Chilled items | Packs de gel (0–4 °C) | Around items | Protects greens, flacons, desserts |
Safety first: how do you prevent incidents in dry ice shipping?
Protect people and space. Use loose‑fit insulated gloves, eye protection, and tongs. Store and open boxes in ventilated areas because CO₂ is heavier than air and can pool. Never place dry ice in sealed glass/metal containers. Dans dry ice shipping, the safest container is insulated yet not airtight.
“Do / Don’t” that reduces risk
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Do: Pre‑cool goods; leave vent paths; add a 24 h buffer of dry ice.
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Do: Add clear “safe handling” cards for recipients.
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Don’t: Tape every seam shut; trap gas; let dry ice touch delicate items.
2025 updates and trends in dry ice shipping
What’s new in 2025: Lighter fiber‑based coolers reduce fuel and emissions, while hybrid PCM + glace carbonique packs extend hold time and prevent over‑freezing. Route analytics cut dwell time, so you need less dry ice for the same lane. CO₂ capture pilots at hubs aim to recycle sublimated gas back into pellets, improving sustainability in dry ice shipping.
What’s moving the needle
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Lightweight shippers: Same performance with less mass to move.
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Hybrid refrigerants: PCM sleeves plus dry ice for dual‑zone control.
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Smarter routing: Fewer handoffs and delays reduce ice consumption.
Market view: As frozen e‑commerce and biologics expand, expect tighter CO₂ handling guidance, more reuse programs, and standardized indicators for vented packaging. Brands that test and document their pack‑outs will outrank competitors on reliability and cost.
FAQ
How to pack dry ice for shipping without damaging products?
Keep dry ice on top and sides, add separators, and vent the box. This avoids freeze burn and pressure spikes during dry ice shipping.
How much dry ice for a 48‑hour lane?
Commencer par 1× payload weight of dry ice, then add 20–30% if routes are hot or complex.
Can I use dry ice with fresh produce?
Oui, but isolate produce with gel packs and a foam barrier so leafy items don’t freeze.
Is there a hard limit for cargo shipments on passenger aircraft?
Baggage limits are strict; cargo uses operator rules and packing instructions. Always follow current IATA guidance and carrier variations.
How should recipients dispose of leftover dry ice?
Let it sublimate in a ventilated area. Never put dry ice in sinks, toilets, or sealed bins.
Résumé & étapes suivantes
Points clés: Use a vented, three‑layer pack; size dry ice by duration and payload; étiquette Et 1845 clearly; and separate chilled vs frozen zones when needed. Test your dry ice shipping design with a small pilot and the weight table above.
What to do now:
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Audit one lane this week and apply the three‑layer method.
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Run a 48‑hour pilot with data loggers and adjust weights.
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Train staff on venting and PPE.
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Standardize labels and recipient instructions. Ready to optimize your dry ice shipping? Get a tailored pack‑out from Tempk today.
À propos du tempk
We design and test temperature‑controlled packaging that keeps products frozen longer with less dry ice. Our team combines lab data and field pilots to optimize dry ice shipping for food, biotechnologie, and e‑commerce. We focus on reliable hold time, clear labeling, and practical handling so your shipments arrive intact and compliant.
Parler à un ingénieur: Book a quick consult and get your lane‑specific pack‑out and weight plan.
