When you need to keep frozen goods solid during transit, you don’t have to rely on messy wet ice or hazardous blocks of dry ice. UN reusable dry ice pack sheet is a flexible cooling pad that you soak, freeze and cut to size. Unlike rigid blocks, these sheets contain sealed cells filled with super absorbent polymers that can maintain ultra cold temperatures down to –21 °C for up to 24 heures. They sublimate directly to carbon dioxide gas, so your packages stay dry, and they can be rehydrated and refrozen multiple times for long term savings. This guide explains how reusable dry ice pack sheets work, how to size and use them safely, and why they’re a smart investment for your cold chain operations.
How do reusable dry ice pack sheets work and what makes them different? We’ll explore their layered construction and explain how sealed cells and super absorbent polymers deliver consistent –21 °C cooling.
How can you size and arrange sheets for optimal performance? Learn the 1:1 sizing formula, seasonal adjustments, and top, surround and hybrid layouts that extend cooling to 72 heures.
What safety and regulatory guidelines apply? Understand ventilation, étiquetage, POINT 49 CFR requirements and carrier rules to ship dry ice responsibly.
How do reusable dry ice sheets compare to gel packs and phase change materials (PCMS)? See the pros and cons of each refrigerant and discover when hybrid packouts make sense.
Quoi 2025 trends are shaping cold chain packaging? Explore innovations like eco friendly insulation, IoT monitoring and AI driven logistics that improve performance and sustainability.
What Is a Reusable Dry Ice Pack Sheet and How Does It Work?
Reusable dry ice pack sheets are flexible pads that you soak in water, freeze and cut to size to keep shipments frozen. Unlike solid blocks, they start as thin, paper like materials composed of small square cells. When immersed in water, the cells absorb moisture and swell into gel pockets; after freezing they provide sustained, ultra cold temperatures down to –21 °C for up to a day. Because the water is locked inside sealed cells, the sheet sublimates into carbon dioxide gas rather than melting into puddles, keeping packages dry.
Layered Construction and Materials
Reusable dry ice pack sheets typically consist of three layers:
| Couche | Composition | Role in Cooling | Ce que cela signifie pour vous |
| Outer layer | Durable polyethylene or non woven fabric | Provides a protective barrier and allows the sheet to be cut or wrapped without tearing | Ensures durability during transit and multiple freeze–thaw cycles |
| Absorbent core | Super absorbent polymers that turn water into gel | Retains water, freezes to form ice and maintains ultra cold temperatures | Allows consistent –21 °C cooling for up to 24 heures |
| Cell structure | Grid of sealed cells that prevent leaks and allow flexibility | Prevents gel leakage and enables sheets to be cut to various sizes | Makes it easy to wrap around irregular objects and reuse the sheet multiple times |
The cell structure is critical to the sheet’s flexibility. When hydrated, the film transforms from a thin sheet into a pliable mat that can conform around products. Its sealed cells stop gel leakage, enabling multiple freeze thaw cycles and reducing waste. Each Techni Ice HDR dry ice sheet, Par exemple, comprises 24 four ply cells—two inner textile sheets containing the refrigerant polymer and two high density plastic sheets—making it FDA approved for contact with food.
Key Features and Benefits
Reusable dry ice pack sheets offer a number of advantages compared with traditional refrigerants:
Prolonged cold retention: Individual sheets maintain temperatures as low as –21 °C for up to 24 heures. Surround or hybrid layouts can extend cooling to 36–72 heures.
Aucun résidu d'eau: As the sheet warms, the dry ice sublimates into carbon dioxide gas rather than melting, preventing soggy packaging and contamination.
Réutilisabilité: Sheets can be rehydrated and refrozen multiple times, offering long term cost savings and reducing environmental waste.
Flexibilité: Sheets can be cut to fit different container sizes and wrapped around irregular shapes, maximizing cooling contact.
Lightweight storage: Dry sheets are thin and lightweight before hydration, saving storage space and reducing shipping costs.
FDA and government approval: Heavy duty reusable dry ice packs like Techni Ice are internationally patented and have FDA approval for safe use with food and perishables. They are trusted by organizations such as the Department of Defence, airlines and medical services worldwide.
How USA Dry Ice Pack Sheets Enhance Delivery Efficiency
Because reusable dry ice pack sheets have no liquid water content, they eliminate the mess associated with melting ice. Traditional wet ice or gel packs melt and can soak through cardboard packaging, damaging labels and compromising product quality. Dry ice sheets sublimate to CO₂ gas, preserving the structural integrity of packaging. They deliver consistent deep freeze temperatures, making them ideal for shipping frozen meats, seafood and pharmaceuticals across the country. Par exemple, a Colorado seafood distributor used these sheets to ship salmon fillets to Florida during summer; by arranging the sheets around the product and insulating with foam, the fish arrived still frozen and free of condensation damage.
Practical Tips for Hydrating and Freezing
Hydrate thoroughly: Immerse the sheet in water for 10–15 minutes until each cell swells. Over soaking wastes water, while under soaking reduces cooling capacity.
Freeze completely: Lay the hydrated sheet flat in a freezer at –18 °C or below for at least 12 heures avant l'utilisation.
Cut and wrap: Use scissors to cut along cell lines to fit around products or line box walls. Ensure complete coverage for even cooling.
Couper correctement: Place the dry ice sheet on top of frozen products so that cold air sinks down. For longer transit times, line the sides and bottom with additional sheets.
Réutiliser de manière responsable: After shipping, let residual CO₂ dissipate in a well ventilated area, then rinse and refreeze the sheet.
Real world example: A Midwest meal kit service began using dry ice pack sheets for cross country deliveries. By hydrating, cutting and layering sheets around vacuum sealed steaks and vegetables, they eliminated soggy boxes, reduced ice consumption by 30 %, and improved customer satisfaction.
How to Calculate and Use Reusable Dry Ice Pack Sheets for Your Shipment?
To ensure products stay frozen without adding unnecessary weight or cost, you must size and arrange dry ice sheets correctly. A simple 1:1 ratio of dry ice sheet weight to product weight provides a starting point for shipments up to 48 heures. Par exemple, expédition 8 pounds of frozen meat would require roughly 8 pounds of dry ice sheets. Adjust this baseline based on seasonal temperatures, route complexity and insulation quality.
Sizing Formula and Seasonal Adjustments
The sizing formula accounts for factors that influence sublimation and thermal loss:
Baseline calculation: Multiply product weight by 1.0 to estimate the starting dry ice sheet weight.
Seasonal factor: Ajouter 35 % extra during summer, 15 % for spring/fall and nothing for winter.
Route factor: Ajouter 10 % for multi hand off routes or 15 % pour les voies chaudes; add zero for direct routes.
Facteur d'isolation: Subtract 10 % when using premium insulation and 25 % when using vacuum insulated panels.
Combined formula: Dry Ice Weight = Product Weight × (1 + Saison + Itinéraire + Isolation).
| Poids du produit | Commencer la glace sèche (1:1) | Additions (Season/Route/Insulation) | Ce que cela signifie pour vous |
| 4 kg | 4–5 lb | Ajouter 35 % in summer and 10 % for multi hand off; soustraire 10 % with premium insulation | Ensures reliable 24–36 hour hold for small shipments |
| 8 kg | 8–10 lb | Add up to 15 % for hot lanes or multi hand off; soustraire 25 % with vacuum panels | Supports 36–60 hour shipments with improved insulation |
| 12 kg | 12–15 lb | For extremely hot conditions, add up to 35 %; premium insulation reduces dry ice weight by 20–25 % | Maintains frozen conditions for 48 heures ou plus |
Layout Strategies: Haut, Surround and Hybrid
How you arrange dry ice sheets affects sublimation rate and cooling duration. Three common layouts include:
Meilleur emplacement: Placing sheets above products achieves sublimation rates of 8–12 % par 24 hours and maintains temperatures for 24–36 hours. Use this layout for short trips or when space is limited.
Surround placement: Lining all sides of the product reduces sublimation to 6–9 % and extends cooling to 36–60 hours. This is ideal for sensitive pharmaceuticals or high value seafood.
Hybrid layout: Combining top and side placement yields the best performance, with sublimation as low as 5–8 % and cooling durations of 48–72 hours. Choose this layout for long distance shipments or when ambient conditions are extreme.
Conseil: Use premium insulation such as vacuum panels or EPS foam to further reduce sublimation. Real time temperature loggers and AI driven analytics can help refine your layout and optimize dry ice usage.
Leveraging Data and Technology
AI driven logistics platforms analyse historical shipping data and ambient temperature records to predict sublimation rates and optimize dry ice quantities. Real time monitoring devices can alert you to deviations, enabling quick intervention to prevent spoilage. Partnering with cold chain experts ensures access to the latest best practices and technology.
What Safety and Regulatory Guidelines Apply to Shipping Dry Ice Pack Sheets?
Shipping dry ice in the United States is subject to strict regulations to protect handlers, carriers and recipients. The Food and Drug Administration (FDA) requires container closure systems to protect products from contamination. The U.S. Department of Transportation’s 49 CFR part 173.196 et 173.199 specify packaging for diagnostic specimens and infectious substances, including triple packaging (primary receptacle, secondary container and outer packaging). Carriers such as UPS, FedEx and USPS impose limits on dry ice weight and require specific labeling.
Ventilation and Container Guidelines
Vent containers: La glace sèche sublimait le dioxyde de carbone, which can build pressure in sealed containers. Never seal dry ice in airtight or glass containers; use ventilated EPS foam boxes or vacuum insulated panels inside sturdy cardboard boxes to allow gas to escape.
Separate contents: Keep contents separate from the dry ice to prevent direct contact damage and maintain cold distribution. UPS recommends 5–10 pounds of dry ice per 24 hours depending on insulation density.
Add extra for delays: Always add extra dry ice to cover unexpected delays.
Labeling and Documentation Requirements
All dry ice shipments require clear labeling. Packages must be marked “Carbon Dioxide, Solide, UN1845” and indicate the net weight of dry ice in kilograms. Airlines limit dry ice in passenger luggage to 2.5 kg (5.5 kg) and require a Class 9 hazard label for packages over 30 kg. UPS and FedEx do not require a Dangerous Goods declaration if dry ice is the only hazardous material, but proper labels and documentation are still essential. USPS allows only domestic shipments and requires labeling with contents and net dry ice weight.
| Carrier/Regulation | Key Rules | Ce que cela signifie pour vous |
| FDA 21 CFR 211.94 (b) | Containers must protect drugs from external contamination | Use leak proof secondary packaging and insulated outer boxes for pharmaceuticals |
| POINT 49 CFR 173.199/173.196 | Triple packaging required for diagnostic specimens | Place dry ice sheets outside the primary receptacle so CO₂ can escape |
| Hauts | Use ventilated EPS containers; 5–10 lb par 24 h; add extra for delays | Leave vents open and avoid over taping; calculate dry ice based on EPS density |
| Compagnies aériennes (Iata) | Label with UN1845, display net weight; 2.5 kg limit for passenger baggage | Pour les envois plus importants, work with cargo services and complete IATA paperwork |
| USPS (Instruction d'emballage 9A) | Domestic shipments only; label with contents and dry ice weight | Confirm route is domestic; abide by weight limit; include hazard label |
Safety Checklist for Handling Dry Ice
Vent containers to allow gas escape; never place dry ice in a sealed glass or metal vessel.
Portez un équipement de protection including insulated gloves and goggles to prevent frostbite and eye injuries.
Use sturdy insulation such as EPS foam or vacuum panels inside a cardboard box.
Label packages clearly with the UN 1845 designation and net weight of dry ice.
Document weight and add extra dry ice to cover potential delays.
Train staff on dry ice handling, CO₂ exposure hazards and emergency response; training is required for anyone who handles dry ice.
Exemple de cas: A diagnostic lab in New York shipped blood samples to California using dry ice pack sheets. By following DOT’s triple packaging rule and labeling the box with the UN 1845 label and net dry ice weight, they ensured the samples arrived frozen and passed regulatory inspection without issue.
Reusable Dry Ice Sheets vs Gel Packs vs PCM Sheets: Qui est le meilleur?
Choosing the right refrigerant depends on your product’s temperature range, shipment duration and sustainability goals. Traditional gel packs, dry ice sheets and phase change material (PCM) sheets each have distinct characteristics.
Comparative Analysis
| Réfrigérant | Plage de température | Durée de refroidissement | Leak Risk | Réutilisabilité | Durabilité | Practical Implications |
| Traditional gel packs | 0 °C à 5 °C | Jusqu'à 6 heures | Modéré; gel can leak when punctured | Limité; often single use | Faible; plastic waste generated | Good for refrigerated products like salads or beverages but unsuitable for freezing |
| USA dry ice pack sheets | –21 °C (pour jusqu'à 24 h) | 24–72 hours depending on layout | Très faible; sublimation leaves no liquid | Oui; rehydrated and refrozen multiple times | Modéré; CO₂ is released but packaging is reusable | Ideal for frozen goods and overnight shipments; requires hazard labels and ventilation |
| PCM sheets | –20 °C to 5 °C | 48–72 heures | Minimal; PCMs do not leak when sealed | Highly reusable; >500 cycles | Haut; often biodegradable and recyclable | Suitable for refrigerated or moderately frozen goods; avoids hazardous labels and reduces carbon footprint |
Why Choose Reusable Dry Ice Pack Sheets?
Reusable dry ice sheets merge the deep freeze capability of dry ice with the flexibility and sustainability of PCMs. They contain high density PCMs that maintain –20 °C to 5 °C, do not leak and can be refrozen hundreds of times. These sheets behave like smart thermostats, adjusting to external temperatures and reducing temperature excursions by 25 %. Businesses using reusable sheets have reduced waste by 60 %, lowered packaging costs and decreased customer complaints about temperature issues.
Tips for Selecting the Right Refrigerant
Identify temperature requirements: Use dry ice sheets for deep frozen goods (below –10 °C). Choose PCMs for refrigerated goods (2 ° C - 8 ° C) and hybrid packouts for shipments requiring multiple temperature zones.
Consider shipping duration: For shipments under 24 heures, dry ice sheets may suffice. For 48–72 hour shipments, hybrid packouts or PCMs can reduce dry ice quantity and regulatory burdens.
Assess reuse and sustainability goals: If your business values circular economy practices, opt for reusable PCM sheets that last 500+ cycles.
Evaluate cost vs compliance: Dry ice requires hazard labels and training; PCMs avoid hazardous classifications but have higher upfront costs. Balance regulatory complexity against cooling needs.
2025 Trends and Innovations in Cold Chain Packaging
The cold chain industry is rapidly evolving. Analysts project the global cold chain market to reach $500 milliards 2025. Growth is driven by pharmaceuticals, biologics and online grocery demand. Entre-temps, the reusable ice pack market is estimated at $800 million in 2025 and is projected to exceed $1.5 milliards 2033, growing at a 7 % TCAC. The global cold chain packaging refrigerants market is valued at $1.69 milliards en 2025 and expected to reach $2.92 milliards 2032 avec un 8.14 % TCAC.
Latest Innovations and Their Significance
Isolation écologique: Manufacturers are developing sustainable insulation materials that reduce environmental impact while enhancing thermal efficiency, including bio based foams, recyclable vacuum panels and compostable linings. Ce que cela signifie pour vous: sustainable insulation can reduce waste and align your brand with environmental goals.
Real time temperature monitoring: IoT enabled sensors provide continuous data on temperature, humidity and location, enabling rapid intervention to prevent spoilage. Some dry ice sheets incorporate RFID tags or smart labels to track temperature history. Avantage: improved visibility and quicker response to deviations.
AI driven logistics: Advanced algorithms analyse shipment data to predict sublimation rates and optimize dry ice quantities. AI platforms also manage routing to avoid delays and extreme conditions. Avantage: lower costs and fewer temperature excursions.
Emballages hybrides: Combining dry ice sheets with PCMs or gel packs creates multi temperature zones within a single shipment. Hybrid layouts extend cooling duration to 72 heures and reduce sublimation rates. Avantage: flexibility for mixed loads.
Sustainability metrics: Businesses are adopting life cycle assessments and carbon footprint tracking for packaging. Reusable sheets and PCMs can cut waste by up to 60 % and lower emissions by 25 %. Avantage: improved ESG performance.
Insistance au marché
Demand for reliable cold chain solutions is surging across the U.S. Online meal delivery, grocery e commerce and biologic medicines all require consistent temperature control. Many businesses are shifting from single use gel packs to reusable dry ice sheets and PCMs to reduce environmental impact and compliance costs. Real time monitoring and AI analytics are becoming baseline expectations for high value shipments. As carriers tighten regulations and consumers demand sustainability, adopting smart, eco friendly dry ice solutions will be essential for staying competitive.
Questions fréquemment posées
Q1: How long do reusable dry ice pack sheets keep items frozen?
Depending on layout and insulation, a hydrated dry ice sheet maintains –21 °C for up to 24 heures. Surround or hybrid layouts can extend cooling to 36–72 heures.
Q2: Can I reuse dry ice pack sheets?
Oui. After the dry ice sublimates, allow residual CO₂ to dissipate in a well ventilated area, then rehydrate and refreeze the sheet. Many sheets withstand multiple freeze thaw cycles, providing long term cost savings and reduced waste.
Q3: Do I need a Dangerous Goods declaration when shipping dry ice sheets?
For domestic shipments of non hazardous goods, you typically do not need a full declaration. Cependant, you must label packages with “Carbon Dioxide, Solide, UN1845” and list the net dry ice weight. International shipments or packages containing other hazardous materials may require a full declaration.
Q4: What should I do if a dry ice sheet comes into contact with food?
Avoid direct contact between dry ice and food. Always separate sheets from products using plastic liners or by placing them on top to ensure even cooling. Direct contact may cause extreme cold damage.
Q5: How do I dispose of used dry ice sheets?
Allow leftover dry ice to sublimate in a well ventilated area away from people and pets. Rehydrate and refreeze the sheet if it is reusable; sinon, dispose of it according to local recycling guidelines.
Q6: Are reusable PCM sheets a better option?
Reusable PCM sheets maintain temperatures between –20 °C and 5 °C and can be refrozen over 500 fois. They don’t require hazardous labels and reduce waste by 60 %, making them suitable for refrigerated or moderately frozen goods. Cependant, they may not achieve the ultra cold temperatures of dry ice sheets.
Résumé et recommandations
Principaux à retenir: Reusable dry ice pack sheets are flexible pads that you hydrate, freeze and cut to size to keep frozen goods solid during transit. Sealed cells filled with super absorbent polymers deliver ultra cold temperatures down to –21 °C for up to 24 heures. Surround or hybrid layouts extend cooling to 36–72 hours. Proper sizing follows a 1:1 ratio of dry ice to product weight, adjusted for season, route and insulation. Compliance with DOT 49 CFR regulations, ventilation, labeling and safety training is essential. Compared with gel packs, reusable dry ice sheets offer deeper cold and reusability; PCMs provide longer duration without hazardous labels. 2025 trends point toward eco friendly insulation, Surveillance de l'IoT, AI driven logistics and hybrid packouts. The reusable ice pack market is projected to grow from $800 million in 2025 to over $1.5 milliards 2033, while the cold chain packaging refrigerants market is expected to reach $2.92 milliards 2032.
Conseils exploitables:
Évaluez les besoins en température de votre produit: Use dry ice sheets for deep frozen goods and PCMs for refrigerated goods. Hybrid solutions offer multi temperature zones.
Apply the sizing formula: Start with a 1:1 ratio of dry ice to product weight and adjust for seasonal factors, route complexity and insulation quality.
Select the right layout: For short trips use top placement; for longer durations choose surround or hybrid layouts.
Suivre la réglementation: Vent containers, label packages with UN 1845 et poids net, and comply with DOT 49 CFR and carrier specific guidelines.
Invest in reusable solutions: Rehydrate and refreeze dry ice sheets to reduce waste; consider PCM sheets for 500+ réutiliser les cycles.
Leverage technology: Use IoT sensors and AI logistics platforms to monitor temperature, predict sublimation and optimize routes.
Consult experts: Partner with cold chain specialists and carriers experienced with dry ice shipments to ensure compliance and efficiency.
À propos du tempk
Tempk specializes in advanced cold chain solutions for the U.S. marché. Notre USA dry ice pack sheets, reusable PCM products and insulated containers are engineered to meet strict FDA and DOT regulations while maximizing cooling performance. We focus on sustainability by offering recyclable materials and reusable products that reduce waste and costs. Let our experienced team help you design an optimal cold chain system—from sizing formulas and layout strategies to real time monitoring and regulatory compliance.
Appel à l'action: Ready to upgrade your cold chain? Contact the Tempk team for a tailored consultation. Our experts will help you choose the right combination of dry ice sheets, PCMs and insulation to meet your specific temperature requirements and sustainability goals.
