How to Choose the Best Dry Ice Wrap for Shipping?
Introduction: Keeping frozen goods or sensitive pharmaceuticals safe during transit requires more than just dry ice; it demands a high performing wrap that slows sublimation, protects contents and vents gas safely. The best dry ice wrap for shipping depends on the product’s temperature range, journey length and environmental goals. Foil bubble liners, paper based insulation and hybrid PCM/dry ice systems are now widely used, replacing the old “newspaper only” approach. This guide explains how to select and pack wraps that keep your goods frozen, using facts from university safety guidelines and industry standards.
What makes a dry ice wrap effective for shipping? We’ll explore insulation materials, venting and how sublimation works.
Which wrap should you choose for different journey durations? Learn how foil bubble liners, foam and paper based CelluLiner compare.
How to pack dry ice safely with the right wrap? Follow step by step instructions for layering dry ice and products.
What are the biggest mistakes to avoid? Avoid sealing containers airtight and positioning dry ice incorrectly.
What innovations are emerging in 2025? Discover eco friendly wraps, hybrid PCM/dry ice systems and IoT monitoring.
What Makes a Dry Ice Wrap Effective for Shipping?
Direct Answer: An effective dry ice wrap insulates to slow sublimation, prevents direct contact with products and vents carbon dioxide gas safely. Dry ice (solid carbon dioxide) sublimates at around –78.5 °C (–109 °F) and leaves no watery residue. To maximize its cooling power, the wrap must trap cold air while allowing CO₂ gas to escape. Foil bubble wrap and high performance liners like Tempk’s CooLiner use metalized films and air bubbles to provide superior thermal insulation, while paper based CelluLiner uses thousands of air pockets to slow heat transfer. Wrapping dry ice loosely in newspaper or brown paper helps pack the refrigerant tightly and slows sublimation, but without proper venting the package can rupture. A good dry ice wrap balances insulation, space efficiency and safety.
Deeper Explanation: When dry ice sublimates, each kilogram absorbs more than twice the heat of water ice, making it ideal for keeping vaccines or frozen food below –20 °C. However, if the wrap traps too much CO₂ gas, pressure can build and rupture the container. University guidelines emphasize that dry ice must be packed tightly with newspaper or paper bags but never sealed in an airtight vessel. Foam or fiber liners provide thick insulation but can be bulky; foil bubble wraps offer a slim radiant barrier suitable for journeys under 24 hours. Paper based liners like CelluLiner keep goods frozen up to 48 hours and are curbside recyclable. Choosing the best wrap involves matching these properties to your shipment’s needs—duration, temperature range and sustainability goals.
Choosing Between Foil Bubble Wrap and Other Insulation
Foil bubble wrap is a modern radiant barrier made from metalized film and air bubbles. Its reflective surface deflects heat, while the trapped air provides additional insulation. This makes it ideal for overnight or day long shipments where weight and thickness must be minimized. Foam or fiber liners such as PopupLiner consist of flexible polyurethane encased in metalized sleeves; they offer robust insulation for up to 96 hours but take up more space. Paper based CelluLiner uses biodegradable paper panels with thousands of air pockets, delivering up to 72 hours of refrigeration and 48 hours of frozen protection. Each material has trade offs:
| Wrap Type | Construction & Insulation | Typical Duration | What This Means for You |
| Foil Bubble Wrap (CooLiner) | Metalized films + air bubbles form a silver “bubble wrap” radiant barrier | ≤24 h | Lightweight and space efficient; perfect for overnight shipments or last mile delivery |
| Foam/Fiber Liner (PopupLiner) | Two metalized sleeves with flexible polyurethane foam | Up to 96 h | Heavy duty for long journeys; ideal for pharmaceuticals or meats traveling cross country |
| Paper Based Liner (CelluLiner) | Biodegradable paper panels with thousands of air pockets | 72 h refrigerated / 48 h frozen | Eco friendly and curbside recyclable; suitable for meal kits and subscription boxes |
| Newspaper/ Brown Paper Wrap | Layers of newspaper or paper bags wrapped around dry ice | Short trips (<24 h) | Low cost and easy to source; must be combined with insulated box and venting |
Practical Tips to Identify the Right Wrap
Match shipping duration to liner thickness: For shipments up to 48 hours, a 1 inch liner works well; for 48–72 hours, increase to 1.5 inches; beyond 72 hours choose a robust solution like PopupLiner.
Consider product temperature requirements: Frozen goods need deeper insulation than chilled items. Use foil bubble wrap for refrigerated goods; upgrade to foam or CelluLiner for frozen shipments.
Think sustainability: If your brand prioritizes environmental responsibility, choose recyclable or reusable wraps like CelluLiner or consider hybrid phase change material (PCM)/dry ice systems that reduce CO₂ emissions.
Account for shipment weight and space: Space is at a premium in air freight. Foil bubble wrap adds minimal thickness while foam liners take up more room but provide longer cold retention.
Real World Insight: In 2025, many meal kit companies switched from traditional styrofoam to paper based CelluLiner to reduce waste. Customers appreciated that the liner could go directly into curbside recycling bins, and complaint rates dropped significantly because food stayed frozen for up to 48 hours.
Key Factors When Selecting Dry Ice Wrap
Direct Answer: Duration, temperature range, container size, regulatory limits and environmental impact determine the best dry ice wrap for your shipment. The longer and colder the journey, the thicker and more robust your insulation must be. For shipments under 24 hours, foil bubble wrap often suffices; for 24–48 hours use a 1 inch foam or fiber liner; beyond 72 hours choose heavier PopupLiner. Always verify that your wrap allows CO₂ gas to vent and meets hazardous materials rules.
Detailed Considerations:
Shipment Duration: The time your package spends in transit directly affects how much dry ice you need and how thick your liner should be. Temperature controlled packaging experts advise 1 inch of insulation for shipments up to 48 hours and 1.5 inches for 48–72 hours. Longer durations require robust liners like PopupLiner.
Temperature Requirements: Vaccines, biologics and gene therapies often need to stay below –70 °C. Foil bubble wrap cannot maintain such extreme temperatures for extended periods, so pair it with thicker foam or hybrid PCM/dry ice systems. For foods that only need to stay below 0 °C, foil bubble wrap or CelluLiner is sufficient.
Payload Size & Shape: Large shipments may benefit from modular or scored wrap sections that conform to irregular loads. Smaller parcels can use pre formed pouches or bricks; ensure minimal air space to slow sublimation.
Compliance & Weight Limits: Air transport restricts dry ice weight to five pounds per parcel, so choose lightweight wraps to maximize coolant. Always label shipments “Carbon Dioxide, solid (dry ice)” and list net weight.
Sustainability Goals: Reusable or recyclable wraps like CelluLiner and hybrid PCM systems reduce waste and long term costs. Evaluate whether the cost premium aligns with your corporate sustainability objectives.
Selecting Wraps by Journey Length
| Journey Length | Recommended Wrap | Reason |
| Same day / <24 h | Foil bubble wrap (CooLiner) | Lightweight barrier reflecting radiant heat; pairs with 5–10 lbs dry ice for quick trips |
| 24–48 h | 1 inch foam/fiber liner or paper based CelluLiner | Balances insulation and space; keeps goods refrigerated or frozen up to two days |
| 48–72 h | 1.5 inch foam/fiber liner (PopupLiner) | Extra thickness provides prolonged cold retention and reduces risk of thaw |
| >72 h | PopupLiner or hybrid PCM/dry ice system | Robust insulation and reusable components for extended or international journeys |
Environmental Considerations
Sustainability is increasingly important. Dry ice sublimation emits CO₂ but leaves no solid waste. Paper based liners like CelluLiner offer curbside recyclability, while reusable foam liners reduce packaging waste over multiple trips. Hybrid PCM/dry ice systems lower total dry ice usage by pre cooling shipments with PCMs and supplementing with dry ice during the coldest portion. Evaluate your carbon footprint and disposal costs when choosing wraps.
Comparing Different Types of Dry Ice Wraps
Direct Answer: Dry ice wraps fall into four main categories: simple paper wraps, foil bubble wraps, foam/fiber liners and paper based liners. Paper wraps offer low cost insulation for short trips but provide minimal barrier and require careful venting. Foil bubble wraps consist of reflective metalized film and air bubbles that provide a thin yet effective radiant barrier. Foam/fiber liners like PopupLiner use flexible polyurethane and provide long lasting insulation, while paper based liners like CelluLiner offer eco friendly insulation using thousands of air pockets.
Detailed Comparison:
Newspaper and Brown Paper Wraps: Traditional guidance from universities suggests wrapping dry ice with newspaper or brown paper bags to pack it tightly and slow sublimation. This method is inexpensive and readily available, but by itself it cannot maintain ultra cold temperatures for long durations. Paper wraps should always be used within an insulated cooler and must allow CO₂ gas to escape.
Foil Bubble Wrap (CooLiner): This wrap uses metalized films laminated onto air bubbles; the reflective surface deflects radiant heat, while the trapped air slows conduction. Foil bubble wraps are thin, easy to handle and ideal for shipments under 24 hours. They pair well with dry ice pellets or slabs to maintain sub zero temperatures. However, because the material is single use and often not recyclable, some companies consider more sustainable alternatives.
Foam/Fiber Liners (PopupLiner): These multi layer liners consist of two metalized sleeves with a flexible polyurethane foam core. They offer superior insulation for up to 96 hours and can collapse for storage, saving warehouse space. PopupLiner panels lock together inside cartons and maintain frozen temperatures during cross country shipments. They require more space and cost but are reusable for many cycles.
Paper Based Liners (CelluLiner): CelluLiner uses biodegradable paper panels with thousands of small air pockets. This structure slows heat transfer, allowing shipments to stay refrigerated up to 72 hours or frozen up to 48 hours. Curbside recyclability provides a sustainable solution for meal kits and subscription services. While not as long lasting as foam liners, CelluLiner meets many businesses’ environmental goals.
Hybrid PCM/Dry Ice Wraps: Emerging wraps integrate PCM panels that maintain specific temperature setpoints with pockets of dry ice for initial cooling. These systems deliver stable temperatures and reduce total dry ice usage. They are reusable and non hazardous, though initial costs are higher.
Table: Wrap Types and Suitability
| Wrap Type | Typical Use Cases | Pros | Cons |
| Newspaper/Paper Bags | Short local shipments, small frozen items | Low cost, easy to source, adds padding | Poor insulation, must vent gas, not suitable beyond 24 h |
| Foil Bubble Wrap | Overnight pharmaceuticals, quick frozen food deliveries | Thin radiant barrier; reflects heat; easy to pack | Single use; not recyclable in all areas; <24 h limit |
| Foam/Fiber Liners | Biological samples, seafood, meat on multi day journeys | Superior insulation up to 96 h; reusable; collapsible | Larger, heavier; higher upfront cost |
| Paper Based Liners (CelluLiner) | Meal kits, grocery subscriptions, eco friendly brands | Curbside recyclable; up to 48 h frozen; thousands of air pockets | Slightly bulkier than foil; may saturate if condensation occurs |
| Hybrid PCM/Dry Ice Systems | Clinical trials, mixed temperature loads | Stable mid range temperatures; reduces dry ice usage; reusable | Higher initial cost; needs careful conditioning |
How to Pack Dry Ice Safely with the Right Wrap
Direct Answer: Follow a layered packing method: freeze products, use insulated containers, separate dry ice from items with cardboard or foam, fill voids with paper, and allow venting. University guidelines instruct placing frozen samples in ziplock bags, wrapping dry ice in paper and placing it at the bottom of the cooler, layering newspaper over the dry ice, then adding the product and padding with crumpled paper. This ensures the cold emanates from the dry ice while preventing direct contact and freezer burn.
Detailed Step by Step Instructions:
Pre Chill Items: Freeze all products before packing to reduce thermal load. Pre chilled items require less dry ice to maintain target temperature.
Prepare the Container: Use an insulated cooler or box with at least 1 inch of foam or fibre insulation for shipments up to 48 hours. Avoid containers with airtight seals; dry ice must vent.
Wrap Dry Ice: Break dry ice into slabs or pellets as needed. Wrap each piece in paper or place in a breathable pouch to slow sublimation. Avoid plastic bags that could become brittle.
Layer the Dry Ice: For many shipments, place wrapped dry ice at the bottom of the container and add a cardboard or foam spacer. Add another layer of dry ice on top of the product for long trips (sandwich method). Always leave space above the dry ice for gas to vent.
Insert Products: Place sealed products (vials, food, or breastmilk) into the container. For delicate items, use secondary packaging or small insulated boxes.
Fill Voids: Fill empty spaces with crumpled newspaper, paper peanuts or recycled kraft paper to reduce air volume and slow sublimation.
Vent and Seal: Close the insulated container but do not tape it airtight. Instead, secure the outer carton with packing tape along the seams while leaving ventilation channels open.
Label and Document: Clearly mark the box with “Dry Ice (UN 1845),” noting the net weight of dry ice. Include “Perishable – Keep Frozen” instructions and comply with DOT/IATA labels.
Example: Shipping Frozen Milk with Dry Ice
Stanford Medicine’s breastfeeding guide provides a practical example for packing frozen milk with dry ice. After placing bottles of milk into ziplock bags and sealing them, the instructions recommend wrapping dry ice in paper, placing it in the bottom of the cooler, layering newspaper over the ice, positioning the milk bags on top, and padding the bottles with more crumpled newspaper. This method prevents direct contact, maintains cold, and utilizes newspaper both as an insulator and as a cushion.
Pro Packing Tips and Solutions
Use cardboard separators: Cardboard or foam pieces between dry ice and products prevent freezer burn and physical damage.
Keep the lid loose: Do not tape down the lid to the Styrofoam box; gas needs to escape to prevent pressure build up.
Avoid placing dry ice at the bottom alone: Cold air sinks, so place dry ice both above and below items for even cooling.
Wear protective gear: Always handle dry ice with gloves and safety goggles to prevent frostbite.
Choose the right amount: Use approximately 5–10 lbs of dry ice per 24 hours of transit, depending on container size and insulation.
Include a thermometer: Insert a temperature strip or data logger to monitor internal temperatures; adjust future shipments based on data..
Safety Guidelines and Common Mistakes to Avoid
Direct Answer: Never seal dry ice in an airtight container, avoid wrapping it in plastic, and fill voids with paper or other materials to slow sublimation. Dry ice sublimates to gas; if trapped, gas buildup can cause rupture. Handlers should wear cryogenic gloves and safety goggles. Shipping carriers restrict the amount of dry ice per parcel to 5 lbs for air transport, so overpacking can lead to regulatory violations.
Do’s and Don’ts for Dry Ice Wraps
| Action | Do | Don’t |
| Wrap material | Use newspaper or brown paper to wrap dry ice and pack tightly; use cardboard separators | Do not wrap dry ice in plastic or airtight bags; they can burst |
| Insulation choice | Match wrap to duration: foil bubble for <24 h; CelluLiner or foam for longer | Don’t rely solely on newspaper for multi day trips; it lacks insulation |
| Ventilation | Leave vent holes or loose flaps so CO₂ gas can escape | Do not tape the insulated box shut or use airtight containers |
| Positioning | Layer dry ice above and below goods; use spacers for even cooling | Don’t place all dry ice at the bottom; cold air won’t circulate |
| Void filling | Fill empty space with crumpled paper or peanuts to slow sublimation | Don’t leave air gaps; empty space accelerates heat transfer |
| Handling | Wear gloves, goggles and protective clothing when handling dry ice | Don’t touch dry ice with bare skin; frostbite can occur |
Common Mistakes
Sealing the cooler airtight: Many novices tape down every seam of the box. This can cause a pressure build up as dry ice sublimates.
Insufficient insulation: Using only newspaper without a proper liner results in rapid sublimation. Always pair paper wraps with an insulated container.
Overpacking dry ice: Too much dry ice can freeze products that only need refrigeration. Use the appropriate weight (5–10 lbs per day).
Ignoring carrier guidelines: Regulations limit dry ice weight per parcel and require proper labeling.
Forgetting to monitor temperature: Without a temperature indicator, you won’t know if your goods thawed during transit. Use thermometers or data loggers.
Latest Developments and Trends for 2025
Trend Overview: The dry ice wrap landscape in 2025 is evolving rapidly. Sustainability drives the adoption of recyclable liners, while high tech sensors and hybrid systems improve cold chain reliability. The shift from one off packaging to reusable systems reduces waste and long term costs. At the same time, regulations are tightening around CO₂ emissions, prompting companies to explore alternatives like PCM or closed loop CO₂ capture. Here are notable trends:
Latest Advances at a Glance
Curbside Recyclable Insulation: Products like CelluLiner use biodegradable paper with air pockets to achieve 72 hours of refrigerated protection while being fully recyclable. Major meal kit and grocery subscription services have adopted them.
Collapsible Foam Liners: PopupLiner’s two piece design collapses for storage and assembles quickly, offering up to 96 hours of cold retention. Companies reduce warehouse space and shipping volume by 75 %.
Hybrid PCM/Dry Ice Systems: Combining PCMs that maintain 2–8 °C or –20 °C with dry ice for the initial cooling phase reduces total dry ice usage and provides stable mid range temperatures.
IoT Temperature Monitoring: Smart sensors integrated into wraps send real time temperature data to shippers, enabling proactive interventions and compliance with 21 CFR Part 11 data requirements.
Lightweight Fiber Coolers: Innovations in fiber based coolers and vacuum insulation panels offer high thermal resistance with lower weight, reducing shipping costs and environmental impact.
Market Insights
Demand for sustainable cold chain solutions is soaring. Consumers and regulatory bodies pressure companies to reduce single use plastics and CO₂ emissions. Businesses are therefore investing in recyclable liners, hybrid systems, and reusables. At the same time, the cost of dry ice fluctuates with CO₂ supply; diversifying to PCM reduces supply risk. International shipments face stricter regulations on hazardous materials, making non hazardous PCM systems attractive. Finally, the rise of direct to consumer eCommerce has increased the volume of small frozen shipments, encouraging carriers to develop specialized packaging programs that standardize wraps and simplify compliance.
Frequently Asked Questions
Question 1: What is the best dry ice wrap for short overnight shipments?
For shipments under 24 hours, foil bubble wrap like CooLiner provides a lightweight radiant barrier that, when combined with dry ice, keeps contents frozen without adding bulk. Ensure the container has at least 1 inch of insulation and fill voids with paper to slow sublimation.
Question 2: Can I wrap dry ice in plastic or foil?
No. Plastic bags become brittle and can burst under low temperatures; aluminum foil can trap gas. Wrap dry ice in newspaper or place it in a breathable pouch. Always allow CO₂ gas to vent.
Question 3: How much dry ice should I use per day of shipping?
A general rule is 5–10 lbs of dry ice per 24 hours, depending on container size and insulation quality. Add 20–25 % extra to account for delays and warmer ambient temperatures.
Question 4: Are paper based liners strong enough for frozen shipments?
Yes. CelluLiner’s paper panels contain thousands of air pockets that provide up to 48 hours of frozen protection. They are curbside recyclable and ideal for meal kits or grocery deliveries.
Question 5: What’s a hybrid PCM/dry ice wrap and when should I use it?
Hybrid wraps combine phase change materials that maintain specific temperature ranges (e.g., –20 °C or 2–8 °C) with a small amount of dry ice for initial rapid cooling. They are reusable, non hazardous, and suitable for shipments requiring stable temperatures over several days.
Question 6: How do I dispose of dry ice and used wraps responsibly?
Let unused dry ice sublimate in a well ventilated area away from people and pets. Recycle paper based liners curbside if accepted. Foam liners can often be returned to the supplier for reuse; check local recycling programs.
Question 7: Do I need special training to ship with dry ice?
Yes. Because dry ice is a hazardous material for air transport, shippers must follow DOT/IATA rules and may need training. Many carriers provide guidelines and training resources.
Summary and Recommendations
Key Takeaways: Selecting the best dry ice wrap for shipping hinges on matching insulation to shipment duration, maintaining proper ventilation and prioritizing safety. Foil bubble wrap suits short shipments; foam or paper based liners extend protection up to 96 hours. Always wrap dry ice in paper, fill voids with crumpled material, and avoid airtight seals. Sustainable options like CelluLiner and hybrid PCM/dry ice systems are gaining traction as companies seek to reduce waste.
Action Plan:
Assess your shipment needs: Determine duration, temperature range and payload size.
Choose an appropriate wrap: For short journeys, opt for foil bubble wrap; for multi day trips, invest in foam, fiber or paper based liners.
Use proper packing techniques: Layer dry ice, separate products with spacers and fill voids with paper.
Follow safety and compliance rules: Wear protective gear, vent containers and adhere to dry ice weight limits.
Explore sustainable solutions: Consider reusable or recyclable wraps or hybrid PCM/dry ice systems to reduce environmental impact.
Monitor and adjust: Use temperature loggers; review data to optimize future shipments.
About Tempk
Company Background: Tempk is a leading innovator in cold chain packaging, providing solutions for food, pharmaceuticals and research materials. Our product range includes foil bubble wraps, reusable foam liners and eco friendly paper based insulation. Through continuous R&D, we develop packaging that balances performance, sustainability and cost. With in house thermal testing and 2025 ready designs, we help customers maintain precise temperatures across thousands of miles.
Our Advantages: We offer customizable insulated box liners, validated cold chain shippers and hybrid PCM/dry ice solutions that reduce waste and cut transportation costs. Our expert team can help you design pack outs tailored to your shipment duration, payload and compliance requirements.
Call to Action: Contact Tempk’s cold chain specialists to discuss your shipping challenges and receive a personalized packaging plan. We’ll help you choose the best dry ice wrap for your application and ensure compliance with 2025 regulations.
