Durable dry ice packs are engineered to keep products frozen for days without leakage or thawing. When used correctly with high quality insulation and proper venting, these ultra cold packs can maintain sub zero temperatures for 24–72 hours. They’re essential for shipping frozen foods, vaccines and biologics because they release cooling energy slowly, prevent moisture damage and comply with 2025 shipping rules. This guide uses clear language and real world examples to help toi calculate the right amount of dry ice, select the best insulation, pack safely and stay ahead of the latest cold chain innovations.
How durable dry ice packs work – understanding sublimation, insulation and why mass matters.
How much dry ice to use for 24–72 hour shipments – simple formulas and tables based on product weight and transit time.
Safety and regulatory requirements – UN 1845 étiquettes, ventilation and hazmat limits.
Hybrid and slow thaw solutions – combining dry ice with gel packs or PCM for multi temperature zones.
Step by step packaging tips – pre freezing, layering and venting to maximize hold time.
2025 trends and innovations – smart sensors, VIP insulation, reusable programs and evolving regulations.
How do durable dry ice packs keep goods frozen for up to 72 heures?
Répondre: Durable dry ice packs rely on a combination of solid carbon dioxide (glace carbonique) and insulation to maintain sub zero temperatures for extended periods. Dry ice sublimates at –78.5 °C and releases cold energy without melting, while insulation slows heat transfer. By using thicker foam or vacuum insulated panels and pre freezing the payload, a properly sized pack can keep products frozen for two to three days. The key is matching dry ice mass to the shipment weight and ensuring CO₂ gas can vent safely.
How sublimation, mass and surface area determine hold time
The longevity of a dry ice pack depends on how quickly dry ice sublimates into gas. Sublimation occurs faster when there is more exposed surface area and higher ambient temperatures. Blocks or slabs of dry ice have smaller surface area relative to their mass, so they sublimate more slowly than pellets. Hybrid packs encase dry ice pellets inside gel or PCM layers; the gel absorbs heat and slows down sublimation, extending hold time to 48–72 heures. More mass equals more cooling energy; a general rule is 5–10 lbs of dry ice per 24 hours for every 10–15 lbs of product. Using reflective liners and filling voids with paper or foam reduces heat leak and adds hours of protection.
| Longevity factor | Impact on sublimation | Practical meaning |
| Ice form (Blocs vs Pellets) | Blocks have less surface area and last longer; Pellets sublimate plus rapidement. | Choose blocks or a combination of blocks and pellets for shipments longer than 48 h. |
| Insulation quality | Vacuum insulated panels (Vips) are up to five times more efficient than polystyrene foam. | Upgrade to VIP or thick PUR for 72 h lanes to reduce required dry ice. |
| Payload pre freezing | Starting with a cold product reduces the cooling load. | Freeze goods to at least –18 °C before packing to extend hold time. |
| Void fill and reflective liners | Tight voids and reflective barriers reduce heat transfer. | Fill empty spaces with paper/bubble wrap and use reflective liners to add 10–14 h of hold time. |
| Ventilation | Allow CO₂ gas to escape to prevent pressure build up. | Use vented lids or punch holes in the outer box to ensure safety and maintain cold air flow. |
Conseils et suggestions pratiques
Pre freeze everything: Freeze your product to at least –18 °C (0 °F) and pre chill the container to slow down sublimation.
Superposer stratégiquement: Place blocks or pellets at the base and around the sides, then add more on top to create a cold “sandwich”.
Remplir les vides: Use bubble wrap or paper to eliminate air gaps; reflective liners can add hours of protection.
Évacuer le conteneur: Never seal dry ice in an airtight box; leave small gaps or use vented lids to allow gas escape.
Étiqueter clairement: Mark packages with “Dry Ice” or “Carbon dioxide, solide,"Et 1845 and the net weight in kilograms.
Exemple de cas: A specialty dessert company switched from loose pellets to a combination of one top block, a thin pellet blanket and a reflective liner. The change extended frozen hold time by 10–14 hours and reduced carrier rejections.
How much dry ice should you use for durable packages?
Répondre: The amount of dry ice depends on the weight of your shipment and the desired duration. Pour les expéditions de nuit, pack roughly half the weight of the payload in dry ice; equal weight keeps goods frozen for up to 48 heures, et 1.5× the payload weight is needed for 72 heures. Another rule is to use 5–10 lbs of dry ice per 24 heures pour chaque 10–15 lbs of product. For meat shipments, Fulfyld suggests 1–2 lbs of dry ice per 3–4 lbs of meat, using larger pellets for slower sublimation. Always add a buffer of 15–25 % to account for high ambient temperatures or weekend delays.
Calculating dry ice quantity and choosing packaging
Dry ice requirements vary with container size and insulation. In a typical Styrofoam cooler, 10 kg (22 lbs) of dry ice lasts 1–2 jours, while doubling to 20 kg (44 lbs) extends cooling to 3–5 jours. The table below summarises suggested packs based on payload weight and transport time:
| Payload weight | Dry ice for <12 HRS | Dry ice for 24–48 hrs | Dry ice for 48–72 hrs | Practical meaning |
| 5 lbs | 3 lbs on top | 5 lbs on top | 10 lbs on top | Add more mass for longer transit; no dry ice needed on bottom for small loads. |
| 10 lbs | 5 lbs | 10 lbs | 15 lbs | Doubling dry ice roughly doubles hold time. |
| 20 lbs | 10 lbs | 20 lbs | 30 lbs | Use equal or 1.5× product weight for 48–72 h lanes. |
| 30 lbs | 10 lbs top + 5 lbs bottom | 20 lbs top + 10 lbs bottom | 30 lbs top + 15 lbs bottom | Spread dry ice around the payload to eliminate warm pockets. |
| 50 lbs | 15 lbs top + 10 lbs bottom | 35 lbs top + 15 lbs bottom | 50 lbs top + 25 lbs bottom | Larger loads require bottom placement to maintain even temperatures. |
Additional factors influence the amount needed:
Température ambiante: High temperatures accelerate sublimation; plan extra dry ice or schedule shipments during cooler times.
Insulation quality: Upgrading from EPS to PUR or VIP reduces the amount of dry ice needed for 72 heures.
Pre freezing and product state: Pre frozen goods require less dry ice than those packed at room temperature.
Packs hybrides: Combining dry ice with gel or PCM can reduce CO₂ usage while maintaining multiple temperature zones.
Conseils et suggestions pratiques
Calculate conservatively: Use the higher end of recommended ranges and add a 24 hour buffer to account for delays.
Match insulation to duration: Utiliser 1–1.5 in EPS/PUR for short trips, 1.5–2 in thick foam for moderate duration and Panneaux VIP for shipments over 72 heures.
Pre cool containers: Chill the empty cooler for at least one hour before packing.
Keep dry ice off food: Use cardboard or trays to separate dry ice from food to prevent freezer burn.
Weigh and label accurately: Record the net mass of dry ice on the package to meet carrier limits and avoid delays.
Real world example: In ambient temperatures of 70 °F (21 °C), a well insulated Styrofoam cooler with 15 livres de glace carbonique kept meat frozen for environ 72 heures. Doubling the ice extended hold time to several days.
What safety measures and regulations apply to dry ice shipping?
Répondre: La glace sèche est classée comme un Classe 9 matières dangereuses (Et 1845). Shipments exceeding 5.5 lbs (2.5 kg) require compliance with 49 CFR ou Instruction d'emballage IATA 954, including hazard labels, vented packaging and documentation. All packages must be marked with “Dry Ice” or “Carbon dioxide, solide,” the UN number and the net weight; air shipments need a 100×100 mm Class 9 étiquette. Proper ventilation prevents pressure build up, and personnel must wear insulated gloves and eye protection when handling dry ice to avoid frostbite and CO₂ exposure. Carriers limit dry ice to 2.5 kg par forfait on passenger aircraft.
Labeling and documentation requirements
Regulations vary by carrier but follow the same principles. The table below summarizes the mandatory marks and their purpose:
| Required mark | Description | Why it’s required |
| Nom d'expédition approprié | «Glace sèche» ou «dioxyde de carbone, Solide" | Identifies the hazardous material and informs handlers. |
| Et 1845 | Four digit number for dry ice | Enables carriers and regulators to classify and track the hazardous substance. |
| Poids net | Kilograms of dry ice | Ensures shipments do not exceed carrier or regulatory limits. |
| Classe 9 étiquette | 100×100 mm diamond hazard label | Required for air transport to indicate miscellaneous hazardous material. |
| Shipper/consignee addresses | Names and addresses of sender and recipient | Provides traceability and ensures packages go to the correct destination. |
Conseils et suggestions pratiques
Use vented containers: Never package dry ice in a sealed plastic bag or airtight container; always provide channels for CO₂ to escape.
Train staff: Educate handlers to wear gloves, goggles and use tongs; frostbite can occur within seconds of contact.
Dispose of dry ice responsibly: Laissez-le sublimer dans une zone ventilée; never place it in sinks or enclosed rooms.
Check carrier rules: Different carriers harmonize ground and air standards but may have specific label size or font requirements.
Combine with gel packs: For shipments exceeding two days, carriers like UPS recommend pairing dry ice with gel packs to slow sublimation and maintain temperatures.
Exemple de cas: Encasing dry ice in sealed cells inside hybrid packs reduces frostbite risks and simplifies paperwork. Passengers on aircraft are limited to 2.5 kg de glace sèche, so sealed cells may exempt some packs from hazard labels.
Should you use hybrid or slow thaw dry ice packs?
Répondre: Hybrid or slow thaw dry ice packs combine dry ice pellets or CO₂ snow with gel or phase change materials (PCM) to extend cooling time and create multiple temperature zones. They’re ideal when you need to ship both frozen and refrigerated items together or when you want to reduce dry ice consumption and hazardous material handling. By embedding dry ice in sealed cells and surrounding it with gel, hybrid packs release cold energy gradually, fourniture 36–72 hours of cooling. Ils sont réutilisables, reduce moisture and frostbite risk, and can help avoid hazardous materials fees.
Benefits of slow thaw dry ice packs
Slow thaw packs offer distinct advantages:
Extended cooling window: Slowing sublimation allows shipments to stay cold for two to three days.
Moisture free and mess free: CO₂ sublimates directly to gas; the surrounding gel prevents condensation.
Reduced hazmat handling: Encapsulated dry ice reduces frostbite risk and may simplify paperwork.
Réutilisabilité: High quality gel sheets can be refrozen over 30 cycles, cutting long term costs.
Multi zone flexibility: Hybrid packs can maintain ultra cold (< –70 °C) and moderate (2–8 ° C) zones in one package.
| Hybrid pack component | Fonction | Benefit to you |
| VIP or foam insulation | Reduces thermal loss and slows sublimation | Extends cooling duration and saves dry ice consumption. |
| Sealed dry ice cells | Provide ultra low temperatures (< –70 °C) and sublimate without residue | Ideal for frozen vaccines, meats and biologics. |
| Gel or PCM layer | Absorbs heat during phase change and maintains steady temperature | Prevents temperature spikes and protects delicate goods from over freezing. |
| Hybrid configuration | Combines dry ice and gel in one pack | Extends cooling to 48–72 hours while reducing CO₂ usage. |
Conseils et suggestions pratiques
Evaluate product needs: Use hybrid packs when you need both frozen and refrigerated zones, such as shipping meal kits containing ice cream and vegetables.
Check reusability: Look for gel sheets that can be refrozen over 30 cycles to cut costs.
Surveiller les températures: Use NFC or Bluetooth sensors to track temperature in real time; hybrid packs often come with pockets for loggers.
Consider cost vs. benefit: Hybrid packs cost more upfront but reduce dry ice consumption by up to 20 %, lowering hazmat fees and carbon footprint.
Suivre la réglementation: Even though some hybrid packs may be non hazardous, always label and vent properly to avoid carrier rejections.
Exemple de cas: A Los Angeles dessert company replaced loose pellets with slow thaw packs and PCM gels. Transit time increased from 36 heures pour 60 heures, CO₂ consumption dropped 20 %, and customer complaints about freezer burn almost disappeared.
How to package dry ice packs correctly for maximum durability
Répondre: Correct packaging maximizes hold time, protects the product and ensures safety. Start by pre freezing your product to at least –18 °C and choosing a rigide, récipient isolé (corrugated box with EPS, PUR or VIP liner). Plan your dry ice quantity (5–10 livres par 24 hours per 10–15 lbs of product) et layer it around the product: place blocks or pellets at the base, add the frozen product and surround the sides and top with more dry ice. Always vent the container, leave small gaps in the tape and avoid sealed plastic bags. Enfin, label the package with the proper name, UN number and net weight, and train staff on safe handling.
Step by step packaging process
Pre freeze and prepare: Freeze the product to –18 °C; confirm it can tolerate ultra cold temperatures.
Select container and liner: Choose a sturdy corrugated box; insert an EPS/PUR liner or upgrade to VIP for long transit or international shipments.
Calculer la quantité de glace carbonique: Use 5–10 lbs per 24 heures, adjusting for product weight and insulation; add a 24 hour buffer.
Layer the dry ice: Place blocks or pellets at the bottom, add the product in a sealed bag, then surround sides and top with additional dry ice.
Vent and close: Seal the liner but leave vent holes; lightly tape the outer box, leaving small gaps for CO₂ to escape.
Label and document: Affix hazard labels, write “Dry Ice/Carbon dioxide, solid” and UN 1845, and state the net weight in kg.
Train and monitor: Educate handlers on using gloves and goggles; include a temperature logger to monitor conditions.
Conseils et suggestions pratiques
Match insulation to duration: Use VIP panels for shipments longer than 72 heures; they can reduce dry ice mass by 20–40 %.
Use layered “sandwich” packing: Placing dry ice at the base, sides and top eliminates warm pockets and cut delivery failures by 38 % in a pastry company case study.
Train customers: Include instructions on safe handling and disposal to prevent frostbite and CO₂ exposure.
Évitez le surpasser: Extra dry ice increases cost and may trigger hazmat limits; aim for the right balance of mass and insulation.
Explore reusable systems: Programs like InfiniDI combine advanced insulation and return logistics to cut dry ice usage by 50 % and reduce waste jusqu'à 90 %.
Exemple de cas: Studies show that foam containers with VIP inserts can retain temperatures for 96–240 hours while reducing dry ice mass by 20–40 %. En outre, layering dry ice as base blocks, side slabs and top pellets reduced warm pockets and decreased delivery failures by 38 %.
2025 trends and innovations in durable dry ice packaging
Aperçu de la tendance
The cold chain landscape is evolving rapidly. Dans 2025, several innovations are reshaping durable dry ice packs:
Hybrid and multi zone packaging: Combining dry ice and PCM materials creates multiple temperature zones in one container.
Advanced gel sheets: New gel sheets hold temperatures of −12 °C to −18 °C for up to 48 heures and can be reused over 30 cycles, offering a cost effective alternative to pure dry ice.
Capteurs intelligents: NFC and Bluetooth temperature loggers provide real time monitoring and alerts.
Eco friendly materials: Manufacturers are developing biodegradable insulation and capturing CO₂ from renewable sources.
Regulatory updates: FSMA deadlines and stricter IATA rules push shippers to adopt vented packaging and improved traceability.
Derniers développements en un coup d'œil
CO₂ supply challenges: Demand for dry ice is growing about 5 % per year while supply increases only 0.5 %, leading to price surges. Hybrid packs help mitigate shortages by reducing CO₂ consumption.
Non hazardous classification: Some hybrid packs encase CO₂ in sealed cells and combine PCM gels, making them non hazardous and exempt from Class 9 étiquettes.
Reusable pack sheets: Flexible dry ice pack sheets deliver –40 °C to –60 °C for 36–72 heures et sont réutilisables.
Croissance du marché: The global cold chain logistics market is projected to grow from $242.39 milliards en 2021 à $647.47 milliards 2028, a compound rate of 15.1 %. Demand for high value perishables and biologics drives innovation.
Insistance au marché
Consumers expect fresh groceries, ready to cook meal kits and sensitive medicines delivered safely to their doorstep. Businesses must reduce spoilage, comply with FSMA regulations and minimise carbon emissions. Durable dry ice packs address these pressures by offering extended cooling, reduced CO₂ usage and improved sustainability. They support e commerce growth by enabling reliable two to three day deliveries and help companies avoid the high cost and complexity of refrigerated trucks. Adoption of VIP insulation and smart monitoring further enhances performance and traceability. Comme 2025 unfolds, shippers who invest in these innovations will gain a competitive edge.
Questions fréquemment posées
Q1: How long will a durable dry ice pack last?
UN: A properly packed dry ice parcel can maintain frozen temperatures for 24–72 heures. En utilisant 5–10 lbs of dry ice per 10–15 lbs of product and high quality insulation extends hold time. Hybrid slow thaw packs can stretch cooling to 36–72 heures with less CO₂.
Q2: Is dry ice safe to touch?
UN: Non. La glace carbonique est extrêmement froide (–78,5 ° C) and can cause severe frostbite on contact. Portez toujours des gants et des lunettes isolés, and handle dry ice with tongs.
Q3: Do I need a shipper’s declaration for dry ice?
UN: Typically not if dry ice is the only hazardous item. You must label the package with “Dry Ice,"Et 1845 et poids net, and attach a Class 9 hazard label for air shipments. Declarations may be required when shipping additional dangerous goods.
Q4: Puis-je réutiliser les packs de glace sec?
UN: The CO₂ itself cannot be re frozen, but many hybrid dry ice pack structures and gel sheets can be reused over 30 cycles. Refillable systems reduce cost and waste.
Q5: Comment puis-je me débarrasser des restes de neige carbonique?
UN: Let dry ice sublimate outdoors or in a well ventilated area. Do not put it in sinks or drains. Gel packs can often be reused or emptied into general waste if non toxic.
Résumé et recommandations
Durable dry ice packs deliver long lasting, moisture free cooling by combining dry ice mass, proper insulation and safe venting. Utiliser half the product weight in dry ice for overnight shipments, equal weight pour 48 hours and 1.5× weight pour 72 heures. For every 10–15 lbs of cargo, allouer 5–10 lbs of dry ice per 24 heures, and add a buffer for delays. Choose insulation based on duration—EPS ou PUR for short trips and Panneaux VIP for long hauls. Pre freeze your payload, layer dry ice around it and always vent packages. Étiquetez avec « Glace sèche,"Et 1845 et poids net. Hybrid slow thaw packs provide flexible temperature zones and reduce CO₂ consumption. Invest in smart sensors, reusable systems and eco friendly materials to stay ahead of 2025 cold chain trends.
Prochaines étapes réalisables
Évaluez vos besoins: Determine your product’s required temperature range and transit duration. Decide whether you need pure dry ice, a hybrid pack or PCM.
Calculate and prepare: Estimate dry ice mass using the guidelines above and pre freeze your product. Choose the right insulation (PSE, PUR ou VIP).
Pack and vent: Layer dry ice correctly, fill voids and ensure vents for CO₂ escape. Avoid overpacking and always separate dry ice from the product.
Label and comply: Mark packages with “Dry Ice,"Et 1845 et poids net; attach hazard labels as required and follow IATA PI 954 pour les expéditions d'air.
Monitor and innovate: Use temperature loggers to track conditions. Explore reusable dry ice programs, smart sensors and VIP insulation to reduce costs and improve sustainability.
À propos du tempk
Company product overview: Nous sommes Tempk, a pioneering provider of cold chain packaging solutions. Our products include gel packs, panneaux isolés sous vide, slow thaw dry ice packs and reusable PCM systems. We combine decades of industry experience with cutting edge research to deliver reliable, eco friendly solutions. VIP liners and hybrid dry ice packs engineered by our team help customers achieve 96–240 hours of cold retention with reduced CO₂ usage. We adhere to international regulations and support clients with compliance training and smart sensor integration.
Appel à l'action: Ready to upgrade your cold chain? Contact Tempk for a personalized consultation. Our experts will help you select the best durable dry ice pack or hybrid solution for your application.
