Dry ice foam dry ice packs blend the ultra low temperatures of solid carbon dioxide with the structural support of foam, creating a versatile refrigerant for modern logistics. In 2025, supply chain managers face dual challenges: keeping sensitive goods within strict temperature limits and meeting sustainability goals amid volatile CO₂ supply. These hybrid packs encapsulate dry ice pellets in foam, slowing sublimation, improving insulation and reducing weight. This article explains how dry ice foam packs differ from bricks and gel packs, explores market dynamics and sustainability trends, and offers practical guidance for safe handling and cost effective use. You’ll also find sector specific tips, innovations like smart sensors and phase change materials, and a look ahead at what the next generation of cold chain solutions might bring.
What distinguishes dry ice foam from other refrigerants? Explore the physics behind foam encapsulation and why it delivers more consistent cooling than loose pellets or gel packs.
How do supply dynamics and sustainability shape the 2025 market? Learn about CO₂ shortages, price volatility and the rise of bio based carbon capture.
Which formats and practices fit different industries? Get sector specific guidance for food, pharma and industrial applications and choose the right format for each.
What are the latest innovations? Discover reusable packs, smart sensors, AI route planning and eco friendly foam materials that are transforming logistics.
How can you minimize risk and maximize savings? Follow safety checklists, layering techniques and disposal guidelines to protect people, products and budgets.
What Sets Dry Ice Foam Apart from Bricks and Gel Packs?
Dry ice foam packs encase carbon dioxide pellets in a lightweight foam matrix, combining ultra low temperatures with enhanced insulation and flexibility. Traditional dry ice bricks are rigid blocks that sublimate slowly, providing 72–120 hours of cooling but limited adaptability. Gel packs, meanwhile, freeze around 0 °C and offer moderate cooling but cannot reach the deep freezing levels required for vaccines or frozen foods. Foam encapsulation solves the mobility and moisture problems associated with loose pellets: it spreads cold evenly across cargo, reduces sublimation by increasing surface area and prevents pellets from settling or rattling during transit. The result is a versatile refrigerant that lasts 48–72 hours and fits irregular shapes without wetting the cargo.
Cooling Technology Comparison for 2025
| Cooling solution | Temperature range | Typical duration | Weight efficiency | Sustainability | Ideal applications | What this means for you |
| Dry ice foam packs | –78.5 °C constant to –18 °C; foam structure slows sublimation | 48–72 hours | Lightweight due to foam | Recyclable foam materials; often made from captured CO₂ | Vaccines, biologics, gourmet seafood; last mile deliveries | Stable ultra cold temperatures without moisture; fits odd shapes |
| Dry ice bricks | –78.5 °C with slow sublimation | 72–120 hours | Heavy and rigid | Reusable; can be returned for multiple cycles | Bulk frozen meat, biological samples needing 96 h storage | Longest duration but less flexible; higher shipping weight |
| Gel packs | 2 °C–8 °C; moderate cooling | Up to 48 hours | Moderate weight | Biodegradable and reusable | Fresh produce, dairy, meal kits | Safer handling and cost effective; cannot freeze items |
The table shows that while dry ice bricks offer the longest duration, foam packs strike a balance between longevity and versatility. They can be refilled with pellets, allowing repeated use, and the foam’s flexibility lets you wrap them around complex shapes, unlike the rigid bricks. Gel packs, though safer and eco friendly, cannot match the –78.5 °C required for deep frozen goods.
How Does Foam Encapsulation Enhance Cooling?
When carbon dioxide sublimates from solid to gas, it absorbs heat and cools its surroundings. Foam encapsulation improves this process by increasing the surface area of the dry ice, allowing more efficient heat absorption without exposing the cargo directly to extreme cold. The foam matrix also acts like a sponge: it absorbs the released CO₂ gas and gradually vents it, preventing dangerous pressure build up and keeping the internal environment stable. For high value pharmaceuticals or delicate seafood, this means fewer cold spots and more predictable temperature control. In addition, the foam’s cushioning minimizes vibration and shock during transport, protecting fragile vials or fillets from damage.
Analogous example: Think of loose dry ice pellets like marbles in a box — they roll around, creating uneven contact and cold spots. Encasing them in foam is like embedding those marbles in a sponge, ensuring each marble touches the product evenly, providing uniform chill and staying put throughout the journey.
Economics and Sustainability of Dry Ice Foam
Market Dynamics and Supply Challenges
The dry ice market is booming but strained. Demand has been climbing at roughly 5 % per year, driven by vaccine distribution, online food deliveries and industrial cleaning, while CO₂ supply has increased only 0.5 % annually. This mismatch causes periodic shortages and price spikes; spot prices surged by up to 300 % during supply crunches. Despite volatility, analysts project the global dry ice market will grow from USD 1.54 billion in 2024 to USD 2.73 billion by 2032, a compound annual growth rate of 7.4 %. Food and beverage shipping, biologics and industrial applications are fueling this growth. Companies therefore must be strategic in how they use dry ice, combining smart packaging, alternative refrigerants and diversified supply contracts to cope with fluctuations.
Bio Based CO₂ Sources and Circular Economy
Supply uncertainty has prompted manufacturers to explore renewable CO₂ sources. Bioethanol plants capture CO₂ emitted during fermentation and convert it into food grade dry ice. In the UK, a single bioethanol facility supplies 30–60 % of the country’s CO₂, demonstrating the potential of circular carbon but also highlighting reliance on a few producers. Trade policies, such as tariff changes that favour imported bioethanol, threaten domestic production and can disrupt local supply. Sustainability pressures are also pushing companies to adopt dry ice foam made from recycled CO₂ and biodegradable foams. These materials lower carbon footprints and align with environmental, social and governance (ESG) goals. Closed loop dry ice production—where captured CO₂ is reused instead of emitted—helps businesses report Scope 3 emission reductions and meet regulatory requirements.
Cost–Benefit Analysis: Why Foam Saves Money
Dry ice foam isn’t just about maintaining temperature—it can reduce spoilage and shipping costs. A seafood exporter using foam inserts reported a 23 % reduction in spoilage and a 12 % drop in shipping costs compared with gel based cooling. Reusable foam structures allow multiple cycles, cutting the cost per shipment. Reusable dry ice packs also offer long term savings: one logistics firm saw a 20 % reduction in cooling costs over six months after switching to reusable dry ice packs. Foam’s lightweight nature lowers freight charges, and its moisture free cooling prevents damage to packaging, saving on product replacement. When weighed against the high price volatility of loose dry ice, foam’s efficiency and reusability provide a compelling business case for 2025 and beyond.
Sector Specific Guidelines for Choosing Dry Ice Formats
The optimal form of dry ice depends on what you’re shipping and how far it must travel. Choosing the wrong format can cause temperature excursions, product damage or unnecessary cost.
Optimal Formats for Different Industries
| Industry and shipment type | Recommended dry ice format | Rationale | Key considerations |
| Meat & seafood processing | Large blocks or slabs | Blocks sublimate slowly and provide long term cooling for bulk shipments. | Invest in better insulated boxes to extend hold times and reduce sublimation. |
| Pharmaceuticals & biologics | Pellets in foam or pack sheets | Pellets cool quickly but vaporize faster; foam moderates the release and prevents supercooling. | Use barrier technologies to slow CO₂ release and integrate real time monitoring to avoid under or over cooling. |
| Industrial cleaning & welding | Pellets or nuggets | Rapid cooling is needed for blasting; pellets offer high surface area. | Secure long term supply contracts to avoid shortages and diversify suppliers. |
| E commerce & meal kits | Foam sheets or hybrid packs | Flexibility allows conforming to various package shapes; hybrid packs combine dry ice with gel or phase change materials. | Hybrid systems prevent freezing of delicate items and help maintain moderate temperatures for mixed loads. |
Packaging Design and Layering Best Practices
Pre condition your containers: Pre chill or pre freeze insulated boxes before loading dry ice. This reduces the initial thermal shock and slows sublimation.
Optimize insulation: Select high performance materials like vacuum insulated panels (VIPs), expanded polypropylene (EPP) or recyclable foams. Thickness and quality directly affect hold time and sublimation rate.
Minimize void space: Fill gaps with foam inserts or thermal fillers to prevent warm air pockets that accelerate sublimation.
Layer strategically: Place dry ice above the payload so that cold air sinks, enveloping the shipment. Surround cargo with foam sheets for even cooling.
Vent appropriately: Use vented lids or breathable membranes to allow CO₂ to escape safely and maintain a maximum concentration below 5000 ppm.
Secure sensors: Integrate data loggers or IoT sensors to monitor internal temperature and gas levels. Real time alerts enable corrective actions before products are compromised.
These practices ensure that whether you choose blocks, pellets or foam, your packaging maximizes thermal performance and safety.
Reusable Dry Ice Packs and Hybrid Systems
Reusable dry ice packs are transforming the cold chain by combining durability with sustainability. Unlike single use foam sheets, these packs feature rigid shells (often high density polyethylene) and integrated phase change materials (PCMs) that buffer temperatures. They can be refilled with dry ice pellets and reused for 10–50 cycles, dramatically reducing waste and long term costs.
Benefits of Reusable Packs
Cost savings: By reusing the same shell multiple times, businesses reduce the cost per shipment. A logistics provider reported a 20 % reduction in cooling costs after six months.
Waste reduction: Fewer disposable components mean less packaging waste. Many reusable packs use biodegradable coatings or recyclable materials.
Enhanced performance: PCMs embedded within the shell help stabilize temperature by absorbing and releasing heat at specific set points. This allows dry ice to last longer and ensures a smooth temperature profile.
Compliance: Durable packs are designed to meet international air cargo standards and are approved for TSA shipping.
Innovations in 2025: Sensors, PCM & AI
The 2025 cold chain is defined by technological convergence. Innovations include:
Biodegradable coatings: Manufacturers are introducing plant based or biodegradable foam coatings to reduce environmental impact.
Smart sensors: Dry ice packs now incorporate IoT devices that monitor temperature, humidity and CO₂ concentration in real time, sending alerts to logistics teams for proactive intervention.
Phase change materials (PCMs): Integrated PCMs provide a secondary cooling plateau, smoothing out temperature variations and extending the life of the dry ice.
Vacuum insulation panels (VIPs): VIP technology reduces heat transfer, meaning fewer ice packs are needed to achieve the same hold time.
AI route planning: Predictive algorithms analyze routes, ambient temperatures and shipment characteristics to recommend optimal quantities of dry ice and schedule replenishment stops.
Carbon neutral manufacturing: Companies are integrating carbon neutral or carbon negative dry ice production methods, such as capturing CO₂ from bioethanol plants and reusing it.
Hybrid Cooling Strategies
Hybrid systems combine dry ice with gel packs or PCMs to tailor temperature profiles. For shipments requiring both refrigeration and freezing — for example, meal kits containing both fresh produce and frozen meat — layering a reusable dry ice pack above a set of gel packs can maintain two zones within one package. Hybrid strategies also reduce the amount of dry ice needed, helping to manage supply volatility and cost. These systems highlight the versatility of dry ice foam and reusable packs in modern logistics.
Safety and Handling Best Practices
Dry ice is classified as a hazardous material (UN1845) due to its extreme cold and sublimation of CO₂ gas. Improper handling can cause frostbite or asphyxiation, so adopting comprehensive safety practices is critical.
Safe Handling and Ventilation
Protective equipment: Always wear insulated gloves and safety goggles when handling dry ice packs. Avoid direct skin contact to prevent frostbite and burns.
Ventilated containers: Use packaging designed with vents or breathable membranes. Never seal dry ice in airtight containers; the buildup of CO₂ gas can cause rupture or suffocation.
Limit CO₂ concentration: In confined spaces such as delivery vans, maintain CO₂ levels below 5000 ppm by ensuring airflow and using gas sensors.
Clear labeling: Mark packages with “Dry Ice – UN1845” and indicate net weight. This alerts carriers and customs officials to handle with care.
Staff training: Train warehouse and delivery personnel on proper lifting techniques, emergency procedures and the hazards of CO₂ exposure.
Automated venting: Consider installing automated CO₂ venting systems in refrigerated trucks or storage units. A case study showed a 30 % reduction in incident rates after implementing such systems.
Disposal and Regulatory Compliance
Proper disposal prevents environmental harm and personal injury. Follow these guidelines:
Allow sublimation: Let unused dry ice sublimate in a well ventilated area until it completely disappears. Do not put dry ice down drains or in enclosed spaces.
Avoid sealing: Never store dry ice in airtight containers; pressure build up can rupture the container.
Wear gloves: Use gloves and eye protection when disposing of dry ice to avoid frostbite.
Follow local regulations: Check disposal guidelines in your area for hazardous materials. Some municipalities require specific procedures.
Recycle packaging: Separate foam, plastic and insulation materials and recycle them whenever possible.
These practices ensure safe handling for workers and compliance with international regulations, while also minimizing environmental impact.
2025 Market and Technology Trends
Growth Forecasts and New Opportunities
The global dry ice logistics market is projected to reach USD 8.7 billion by 2025, growing at roughly 7.4 % CAGR. Driving forces include vaccine distribution, cross border seafood trade and the rise of meal kit services. Cold chain packaging overall is forecast to surpass USD 27 billion in 2025 as e commerce expands and consumers demand fresher products delivered to their doorstep. Sustainability is becoming a central competitive differentiator: regulators and customers increasingly expect transparent carbon accounting and eco friendly materials.
Emerging Innovations
Smart sensors and IoT: Integrated sensors track temperature, humidity and location data, sending alerts for corrective action in real time.
AI and predictive analytics: Route optimization algorithms factor in weather, traffic and product sensitivity to suggest optimal cooling loads and replenishment points.
Bio based foams: Next generation packaging uses foams derived from plant sources or captured CO₂, minimizing fossil inputs.
Automated refreezing stations: Logistics hubs are experimenting with machines that refreeze reusable packs between legs of a journey, ensuring consistent performance without manual intervention.
Last mile cold delivery solutions: E commerce platforms and meal kit services are investing in small, insulated containers with dry ice foam and smart monitoring to manage deliveries in dense urban areas.
These innovations, combined with regulatory changes and consumer expectations, are shaping a more resilient and sustainable cold chain ecosystem for 2025 and beyond.
Frequently Asked Questions
Q1: How long can dry ice foam packs maintain ultra cold temperatures?
Dry ice foam packs typically hold –78.5 °C to –18 °C for 48–72 hours, depending on ambient conditions and insulation. Their foam structure slows sublimation, extending duration by up to 30 % compared with loose pellets.
Q2: Are reusable dry ice packs cost effective?
Yes. Reusable packs with HDPE shells and PCMs can be refilled for 10–50 cycles, and businesses have reported cost reductions of 20 % or more within six months.
Q3: What safety precautions should I follow when shipping with dry ice foam?
Always wear gloves and goggles, use vented containers, label packages with UN1845, maintain CO₂ concentrations below 5000 ppm and train staff on emergency procedures.
Q4: How can I calculate the right amount of dry ice foam?
A general guideline is 0.5–1 kg of dry ice per kg of product per day, adjusted for insulation quality and climate. For hybrid shipments, reduce dry ice and add gel packs or PCMs to fine tune temperature ranges.
Q5: Does dry ice foam support sustainability goals?
Yes. Many foam packs are made from recycled CO₂ and recyclable polymers. Closed loop carbon use and biodegradable coatings reduce environmental impact, and their reusability cuts packaging waste.
Q6: Can dry ice foam be used for air freight?
Dry ice foam packs comply with GDP and IATA regulations for air transport and provide stable ultra cold conditions without liquid residue.
Q7: How does AI improve dry ice logistics?
Predictive analytics analyze route data, ambient temperatures and product sensitivities to recommend optimal pack sizes, reducing over packaging and ensuring products stay within specification.
Summary and Recommendations
Dry ice foam dry ice packs stand at the crossroads of performance, sustainability and cost savings. By encasing pellets in a flexible foam, they provide stable ultra low temperatures, reduce sublimation and cushion your cargo. Compared with bricks, foam packs offer greater flexibility and lower weight, while outperforming gel packs for deep frozen goods. The 2025 market context—characterized by CO₂ supply constraints, price volatility and growing demand—makes efficiency and sustainability paramount. Businesses that adopt dry ice foam and reusable packs can reduce spoilage by 23 %, cut shipping costs by 12 % and meet ESG goals through recycled materials.
To leverage these benefits:
Choose the right format: Match blocks, pellets or foam to your product and route, considering duration and temperature sensitivity.
Invest in insulation and monitoring: Pre condition containers, minimize voids, and use smart sensors to catch temperature deviations early.
Adopt reusable and hybrid systems: Reusable packs with PCMs and VIPs extend hold times and cut costs. Combine dry ice foam with gel packs for mixed loads.
Follow safety protocols: Wear protective gear, vent containers, label shipments and train staff.
Plan for sustainability: Source recycled CO₂, choose biodegradable foam materials, and monitor your carbon footprint.
By following these recommendations, your cold chain operations can stay ahead of supply shortages, comply with stringent regulations and meet customer expectations for quality and sustainability.
About Tempk
Tempk is a global leader in temperature controlled packaging and logistics. Our solutions span dry ice foam packs, reusable PCM packs, gel packs and high performance insulated shippers. We focus on innovation, safety and sustainability, integrating smart sensors, carbon neutral materials and modular designs to meet the evolving needs of pharmaceuticals, biotechnology, food and e commerce clients. With robust R&D and stringent quality assurance, we help partners maintain product integrity, reduce costs and achieve their environmental goals.
Call to action: Interested in enhancing your cold chain strategy? Reach out to Tempk for a customized consultation on implementing dry ice foam and reusable packs.
