Shipping your products at ultra low temperatures used to mean dealing with dry ice. However, supply constraints and safety concerns are pushing businesses toward dry ice replacement dry ice packs. These flexible packs maintain temperatures as low as −40 °C for up to 72 hours without the mess or hazards of solid CO₂. Dry ice consumption is growing 5 % per year while CO₂ supply is expanding just 0.5 %, causing price spikes. If you need a reliable way to keep food, pharmaceuticals and biological materials frozen in 2025, it’s time to explore modern alternatives. This guide explains everything you need to know—what these packs are, why they’re better than old school dry ice, and how to choose, pack and use them safely.
Why are dry ice replacement packs a smarter choice than traditional dry ice?
How do you select the right dry ice replacement pack for various temperature sensitive products?
What packing techniques maximize cooling performance and safety?
Which 2025 innovations, market trends and regulations affect dry ice replacement?
What are the most common questions about safety, usage and sustainability?
Why Choose Dry Ice Replacement Packs Over Traditional Dry Ice?
Dry ice has been the go to refrigerant for decades, but its extreme cold and sublimation behavior pose significant risks. Dry ice replacement packs deliver comparable cooling without hazardous handling or environmental drawbacks. This section explains why these alternatives are gaining ground in 2025.
Advantages Over Traditional Dry Ice
Dry ice replacement dry ice packs maintain sub zero temperatures for 36–72 hours and eliminate liquid residue. Instead of loose pellets that sublimate rapidly, packs encase CO₂ snow or engineered refrigerant in durable cells. This design extends cooling duration, minimizes CO₂ vapor release and allows reuse. By avoiding direct contact with solid CO₂, the packs reduce frostbite risk and simplify handling. Unlike traditional dry ice, which qualifies as a Class 9 hazardous material requiring hazmat training and strict labeling, most replacement packs are non hazardous and exempt from stringent regulations.
Dry ice replacement packs also address supply concerns. Global dry ice demand is rising around 5 % annually, while CO₂ supply increases only 0.5 %, causing shortages and price surges of up to 300 %. Replacement packs use fewer CO₂ resources and incorporate phase change materials (PCMs) or gel refrigerants, offering a more sustainable supply chain.
Understanding How Replacement Packs Work
Replacement packs come in several formats:
| Pack Type | Core Cooling Material | Temperature Range | Typical Duration | Key Benefit |
| Dry ice pack sheets | Solid CO₂ pellets sealed in flexible cells | −40 °C to −60 °C | 36–72 hours | Reusable design; minimizes vapor release |
| Gel/PCM packs | Phase change gels formulated to melt/freeze at set temperatures | 0 °C to −20 °C (chilled) or −15 °C to −26 °C (frozen) | 24–96 hours | Stable temperature bands; reusable and non hazardous |
| Cryogenic gel packs | Cryo Ice™ proprietary gel refrigerant | Below −3 °C, staying under 25 °F (−3.9 °C) during thaw | Up to 48 hours | Safe handling, no hazmat training required |
| Eutectic plates | Pre cooled plates containing PCM | Customizable (frozen or chilled) | 36–72 hours | Robust, reusable and ideal for repeated shipments |
How they work: Each pack type absorbs heat as it melts or as CO₂ sublimates inside the pack, maintaining a steady internal temperature. Dry ice sheets combine rapid cooling from CO₂ pellets with extended hold times due to the sealed cells. Gel packs and PCMs absorb latent heat during phase change, providing narrow temperature ranges that prevent over freezing of sensitive products. Some hybrid packs blend CO₂ cells and PCMs to deliver both ultra cold startup and sustained cooling.
Comparing Dry Ice and Replacement Packs
| Metric | Traditional Dry Ice | Replacement Dry Ice Pack |
| Temperature | −78.5 °C (pellets) | −60 °C to −20 °C depending on design |
| Cooling Duration | 24–48 hours | 36–72 hours (pack sheets); 24–96 hours (PCMs) |
| Regulatory Classification | Hazardous (UN 1845, Class 9) requiring hazmat labeling and training | Generally non hazardous; simpler documentation and handling |
| Handling Risks | Frostbite, CO₂ build up leading to asphyxiation or explosion | Minimal frostbite risk due to sealed design |
| Reusability | Single use; sublimates entirely | High quality sheets and PCM packs can be refrozen and reused |
| Supply Constraints | Dependent on CO₂ availability; price volatility up to 300 % | Diversified sources such as gel refrigerants and PCMs; less sensitive to CO₂ shortages |
Real World Scenario
Case Study: A specialty dessert company in Los Angeles shipped frozen cakes nationwide. In 2024 they relied on dry ice pellets but faced shortages and price hikes. After switching to dry ice pack sheets combined with PCM gel packs, they extended transit times from 36 to 60 hours, reduced CO₂ use by 20 % and eliminated hazmat fees. Customer complaints dropped because cakes arrived intact without freezer burn or water residue.
Practical Tips for Choosing Alternatives
Assess temperature needs: If your products require ultra cold conditions (below −60 °C), a small amount of dry ice or cryogenic gel may still be necessary. For most frozen foods, PCMs or pack sheets maintain −20 °C to −40 °C effectively.
Consider shipment duration: Pack sheets and PCM plates can be layered to reach 72 hours or more; for longer transits or international shipping, combine with active refrigeration or add extra packs.
Optimize reusability: Choose durable packs that can be refrozen—these reduce waste and lower long term costs.
Check regulatory status: Confirm whether the pack is classified as hazardous. Non hazardous alternatives avoid the labeling, documentation and training requirements mandated for dry ice.
How to Select the Right Dry Ice Replacement Pack for Your Shipment
Choosing the perfect replacement pack depends on product type, shipment duration, and regulatory constraints. This section offers a clear framework to guide your decision.
Key Factors to Consider
- Temperature sensitivity– Different goods require specific temperature ranges. Ultra cold pharmaceuticals need temperatures below −60 °C, while frozen foods typically need −20 °C to −40 °C. Dry ice pack sheets and cryogenic gel packs deliver the lower range, whereas PCM gel packs maintain narrower bands around −20 °C.
- Shipping duration– The longer the trip, the more refrigerant you’ll need. A rule of thumb is 5–10 kg of dry ice (or equivalent pack capacity) per 24 hours for 100 liters of container volume. When using pack sheets, estimate one 24 cell sheet per 12 hours of cooling. For long distance or international shipments, consider layering pack types and using additional insulation to stretch cooling time.
- Product size and weight– Larger shipments require more cooling power. Table 2 adapts weight and sheet recommendations from industry guidelines.
| Container Volume | Suggested CO₂ Pellets | Number of Pack Sheets | Expected Hold Time |
| 10 L | 0.75–1 kg | 1 sheet | ≈12 hours |
| 20 L | 1.5–2 kg | 2 sheets | ≈24 hours |
| 30 L | 2.5–3.0 kg | 3–4 sheets | ≈36 hours |
| 40 L | 4–5 kg | 4–5 sheets | ≈48–72 hours |
- Regulatory and safety requirements– Air transport restricts dry ice to 2.5 kg per passenger aircraft and up to 200 kg on cargo flights. Non hazardous packs bypass these limits and simplify paperwork. If shipping internationally, verify compliance with International Air Transport Association (IATA) rules and customs regulations.
- Sustainability goals– Environmental pressures are driving companies to reduce CO₂ emissions. PCMs and gel packs produce less carbon emissions, and some suppliers use renewable bio based CO₂ captured from ethanol fermentation. Evaluate the carbon footprint and recyclability of the packs you choose.
Selecting by Product Category
Frozen Foods and Meal Kits
For seafood, meats and prepared meals requiring −20 °C to −40 °C, dry ice pack sheets are ideal. They maintain freezing conditions for 24–48 hours without producing melt water. Because they release CO₂ gradually, pack sheets prevent freezer burn and maintain product texture. Combine with PCM gel packs to extend duration beyond 72 hours or to maintain specific temperature bands for delicate foods.
Pharmaceuticals and Biologics
Pharmaceuticals often demand ultra cold temperatures (−70 °C or below). Dry ice pellets remain indispensable for vaccines and biologics that cannot tolerate warmer conditions. However, combining pellets with pack sheets can reduce overall dry ice consumption while maintaining required temperatures. For less temperature critical medicines, reusable PCM shippers are gaining traction because they avoid hazardous classification and offer more stable temperature profiles.
Biotechnology and Lab Samples
Biotech samples and cryogenic materials require precise temperature control and fast cooling. Pellets deliver rapid temperature drops and allow precise dosage adjustments. To extend hold times, pair pellets with PCM plates or gel packs and use vacuum insulated containers. Real time sensors (IoT devices) can monitor temperature deviations during transit.
Specialty Foods & Desserts
Products such as gourmet chocolates and ice cream need a narrow temperature band to avoid texture and appearance changes. PCM gel packs designed for −15 °C to −20 °C maintain stability without over freezing. Because gel packs don’t sublimate, they prevent condensation and maintain product quality.
Tips to Maximize Cooling Performance
Pre condition containers: Chill your cooler or carton before packing to slow sublimation and extend cooling by up to 15 %.
Layer correctly: Place pellets or pack sheets at the bottom, add a buffer (cardboard or foam), then your product, and finish with more packs on top. Cold air sinks, so top layers ensure even cooling.
Fill void spaces: Use bubble wrap or dunnage to eliminate air pockets that accelerate heat transfer.
Allow ventilation: Provide vent holes or breathable insulation; never seal CO₂ in an airtight box—pressure build up can cause rupture.
Real World Example: A biotech start up shipping enzyme samples pre chilled its insulated boxes overnight, added a corrugated buffer and layered three 24 cell pack sheets. Temperature logs showed the payload stayed at −25 °C for 60 hours, meeting regulatory requirements without using any dry ice.
Packing and Handling Dry Ice Replacement Packs Safely
Proper packing maximizes performance and ensures worker safety. Although dry ice replacements are less hazardous than traditional dry ice, they still require care.
Preparation and Freezing
Hydrate reusable sheets: Soak reusable dry ice sheets in water before freezing to activate the cells. Freeze them flat to ensure an even shape.
Freeze PCM and gel packs completely: Always freeze packs for the recommended time—typically 24–48 hours—to reach the intended temperature range.
Organize by size and weight: Prepare the right number of packs based on container volume and shipment duration (see Table 2 above).
Packing Sequence
Bottom Layer: Place pellets or a pack sheet at the bottom of the insulated container for rapid cooling.
Buffer Layer: Add cardboard or foam board to prevent direct contact and freezer burn.
Product Placement: Position your product with cushioning materials to eliminate empty spaces.
Top Layer: Add additional pack sheets or pellets on top; cold air sinks, so top placement ensures even cooling.
Ventilation: Ensure the container isn’t airtight to allow CO₂ gas to escape; some designs include built in vents.
Personal Protective Equipment (PPE)
While dry ice replacements reduce frostbite risk, wear insulated gloves and goggles during packing to protect skin and eyes. For gel packs kept below −20 °C, gloves will prevent cold burns; goggles protect against accidental splashes when hydrating reusable sheets.
Labeling and Compliance
Dry ice replacement packs are generally non hazardous, yet clear labeling helps handlers understand temperature management. For shipments using both dry ice and replacement packs, include the net weight of dry ice and hazard labels as required by IATA. Always list the number of packs and recommended handling instructions on the manifest.
Disposal and Reuse
Refreeze: High quality pack sheets and PCM packs can be refrozen and reused multiple times.
Gel pack disposal: If the gel is biodegradable, follow local waste rules; some can be punctured, drained and disposed of with normal waste.
Dry ice disposal: If you have leftover dry ice, let it sublimate in a well ventilated area. Do not store in sealed containers.
Case Study: A pharmaceutical distributor trained its staff to hydrate, freeze and pack reusable dry ice sheets. After switching from loose pellets, the team reduced injuries and regulatory paperwork, while packaging waste dropped by 30 %. Inventory management improved because the packs could be frozen in bulk and used on demand without the rush to beat dry ice sublimation.
2025 Trends and Innovations in Dry Ice Replacement
Cold chain logistics is evolving rapidly, and 2025 brings new technologies, sustainability initiatives and market dynamics that influence how you cool and ship products.
Industry Dynamics and Market Growth
The dry ice market faces supply constraints and sustainability pressure. Demand has been climbing roughly 5 % per year while CO₂ supply grows only 0.5 %, creating shortages and spot price spikes of up to 300 %. The global dry ice market was valued at USD 1.54 billion in 2024 and is projected to reach USD 2.73 billion by 2032 with a compound annual growth rate of 7.4 %.
However, the dry ice alternative solutions market is growing even faster. Recent research reports that this market reached USD 2.34 billion in 2024 and is expected to grow at 8.7 % annually, reaching USD 5.01 billion by 2033. Growth is driven by regulatory pressure for eco friendly logistics, e commerce expansion and rising demand for temperature sensitive products.
Sustainability and CO₂ Capture
Sustainability is shaping cold chain strategies. Clients expect suppliers to cut carbon emissions, prompting manufacturers to explore bio based CO₂ sources and carbon capture. Bioethanol plants capture high purity CO₂ released during fermentation and convert it to dry ice. This creates a circular supply chain and reduces reliance on fossil derived CO₂. Still, over dependence on a few producers risks supply disruptions—such as the UK example, where major CO₂ producers faced geopolitical and trade pressures.
Hybrid Cooling Systems
Hybrid cooling systems that combine dry ice, pack sheets and PCMs are gaining traction. Layering pellets, pack sheets and PCM packs extends hold times by 25 % while reducing dry ice consumption by 18 %. In 2025, shippers are also investing in improved insulation (vacuum panels and curbside recyclable materials) to reduce refrigerant needs.
Smart Packaging and IoT Sensors
IoT technology is transforming cold chain monitoring. Sensors embedded in packaging provide real time data on temperature, humidity and location, enabling proactive intervention and regulatory compliance. Smart packages can alert recipients if the temperature deviates from set ranges, reducing spoilage and ensuring product integrity.
Regulatory and Safety Trends
Stricter environmental regulations are encouraging adoption of non hazardous refrigerants and recyclable materials. Some countries are limiting CO₂ emissions or imposing taxes on carbon intensive logistics, pushing businesses toward gel packs and PCM solutions. Meanwhile, IATA continues to enforce weight and labeling limits on dry ice shipments.
Market Insights by Region
North America dominates the dry ice alternative market due to advanced logistics infrastructure and stringent environmental regulations.
Europe follows closely, driven by sustainability mandates. Bio based CO₂ supply and innovations in packaging are helping mitigate supply constraints.
Asia Pacific is emerging as a lucrative market because of rapid urbanization, growing healthcare demand and expanding e commerce.
Frequently Asked Questions (FAQ)
Q1: Are dry ice replacement packs safe to handle?
Yes. Replacement packs are generally non hazardous and safer than traditional dry ice. They eliminate direct contact with solid CO₂, reducing frostbite risk. Nevertheless, wear insulated gloves when handling packs chilled below −20 °C, and ensure adequate ventilation when using dry ice‐based sheets.
Q2: How long do replacement packs stay cold?
Duration depends on pack type and conditions. Dry ice pack sheets hold temperatures for 36–72 hours, while PCM gel packs can provide 24–96 hours of cooling. Layering multiple packs and pre conditioning containers can extend this period.
Q3: Can I reuse dry ice replacement packs?
High quality pack sheets and PCM packs are designed for multiple uses and can be refrozen. Gel packs may be reused as long as the packaging remains intact; eventually, performance diminishes and packs should be replaced.
Q4: Are replacement packs environmentally friendly?
Yes. Many packs use biodegradable gels or recyclable materials and produce less carbon emissions than traditional dry ice. PCMs and gel packs avoid CO₂ vapor release and reduce reliance on fossil derived CO₂. Additionally, some manufacturers capture CO₂ from bioethanol plants, creating a circular supply chain.
Q5: When should I still use traditional dry ice?
Dry ice remains necessary for ultra cold conditions (below −70 °C) such as certain vaccines, cryogenic samples and industrial cleaning. In these cases, combining pellets with pack sheets and PCM packs can reduce total dry ice usage while maintaining required temperatures.
Summary and Recommendations
Dry ice replacement packs offer a safer, more sustainable and versatile solution for cold chain logistics in 2025. Their ability to maintain sub zero temperatures for 36–72 hours, reduce CO₂ use and minimize regulatory burdens makes them a smart choice for food, pharmaceuticals and biotech shipments. When selecting a pack, evaluate your product’s temperature needs, shipment duration, container volume and sustainability goals. Hybrid systems combining pellets, pack sheets and PCMs can extend hold times by up to 25 % while reducing dry ice consumption.
Actionable Steps
Assess your needs: Define the required temperature range and shipping duration for your product. Use Table 2 to estimate the number of packs or pellet weight.
Choose the right pack type: For ultra cold shipments, consider dry ice pellets and pack sheets. For typical frozen foods or pharmaceuticals, PCM or gel packs suffice.
Plan packing logistics: Pre chill containers, layer packs correctly and ensure ventilation to maximize performance.
Monitor and optimize: Use IoT sensors to track temperatures and adjust pack quantities accordingly.
Adopt sustainable practices: Source packs made from recyclable or bio based materials and evaluate suppliers that capture CO₂ from renewable sources.
About Tempk
Tempk is a leading provider of advanced cold chain solutions, specializing in dry ice replacement packs, gel packs and smart packaging systems. We combine scientific expertise with rigorous testing to deliver products that maintain precise temperatures, reduce waste and comply with international regulations. Our reusable dry ice pack sheets and PCM gel packs are engineered for 36–72 hours of cooling, offering reliable performance for food, pharmaceuticals and biotech shipments. With a focus on sustainability, Tempk sources bio based CO₂ and recyclable materials, helping clients reduce their environmental footprint.
Call to Action
Ready to upgrade your cold chain? Contact Tempk’s experts to discuss dry ice replacement dry ice pack options tailored to your needs. We’ll help you choose the right pack type, plan shipment logistics and stay ahead of 2025 trends.
