Durable Dry Ice Pack Sheet Guide 2025 –How It Transforms Shipping
Keeping food, medicine and laboratory samples at the right temperature during
transport is a core challenge of the cold chain. A durable dry ice pack
sheet combines flexibility, lightweight storage and deep freeze performance to
solve that problem. Unlike rigid blocks that melt into puddles, these sheets
absorb water, freeze to –21 °C and then sublimate directly into carbon
dioxide, leaving no liquid mess. The sealed cells
allow multiple freeze–thaw cycles, making them reusable and eco friendly. This guide
explains what makes dry ice sheets different, how to use them safely and how
2025 innovations will shape the cold chain industry.
What distinguishes a durable dry ice pack sheet from other cooling media?
We’ll explore the three layer construction, non toxic materials and
prolonged cold retention.
How do you choose the right sheet size and layout for your shipment?
Learn practical sizing formulas and placement strategies to keep products
frozen for 24–72 hours.
What safety and regulatory guidelines apply when shipping with dry ice?
Understand FDA and DOT rules, labeling requirements and proper
ventilation.
How do dry ice sheets compare with gel packs and phase change materials?
See a side by side comparison of temperature ranges, leak risks and
sustainability.
Which 2025 trends will affect cold chain packaging?
Discover innovations like eco friendly insulation, smart sensors and
AI driven logistics.
What Makes a Durable Dry Ice Pack Sheet Different?
Direct answer
A durable dry ice pack sheet is a flexible cooling pad made from non toxic
materials that can be soaked, frozen and cut to size to deliver –21 °C
temperatures without leaving any liquid. The sheet typically consists of
three layers: an outer layer of polyethylene or non woven fabric; a core
containing super absorbent polymers that turn water into gel; and a grid of
cells that prevents leakage and allows the sheet to be cut or folded. When hydrated and
frozen, it stays thin yet provides deep freeze cooling for up to 24 hours
. Because the water is locked inside sealed cells, the ice
sublimates directly into carbon dioxide gas rather than melting, keeping
packages clean and dry.
Deeper explanation
Traditional ice blocks or gel packs can be bulky and often leak when they
thaw, soaking cardboard boxes and product labels. Dry ice sheets start as
paper thin mats that absorb water and swell into gel pockets; after freezing
they conform closely to the shape of the cargo. This flexibility
allows you to wrap them around irregular products or line the walls of a box,
maximizing contact and improving heat transfer. The outer layer is
puncture resistant and can be customized in thickness and material to match
your shipment’s needs. Because the polymers are enclosed
within sealed cells, the sheet is leak proof and safe for food and
pharmaceutical use. Many manufacturers, such as Tempk, use
biodegradable outer bags to reduce environmental impact. The
result is a cooling medium that’s lighter, cleaner and more sustainable than
traditional dry ice pellets.
Key components and benefits
| Component | Data/Description | Impact on your shipment |
| Absorbent core | Super absorbent polymers capture water and turn it into gel, providing sustained cold down to –21 °C for up to 24 hours. | Maintains frozen temperatures long enough for overnight shipments without refreezing. |
| Sealed cell grid | The sheet is divided into small squares that prevent gel leakage and allow the mat to be cut or folded without spilling. | Wraps tightly around products and fits various box sizes, enhancing cooling contact and reducing waste. |
| Durable outer layer | Made from polyethylene or non woven fabric; flexible yet puncture resistant and often biodegradable. | Protects the refrigerant, allows multiple freeze–thaw cycles and aligns with sustainability goals. |
Practical tips and advice
Hydrate thoroughly: Immerse each sheet in water for 10–15 minutes until all cells swell. Under soaking reduces cooling capacity.
Freeze completely: Lay the hydrated sheet flat in a freezer at –18 °C or below for at least 12 hours before use.
Cut and wrap: Use scissors to cut along cell lines to fit around products or line box walls. Full coverage ensures even cooling.
Layer correctly: Place sheets on top of the goods so cold air sinks; for longer transit times, line all sides with additional sheets to create a surround or hybrid layout.
Vent safely: After shipment, let residual CO₂ escape in a well ventilated area, then rinse and refreeze the sheet for reuse.
Real world case: A Midwest meal kit service switched from bulky gel packs to dry ice sheets for cross country deliveries. By hydrating, cutting and layering sheets around vacuum sealed steaks and vegetables, they eliminated soggy boxes and reduced ice consumption by 30%, boosting customer satisfaction.
How to Choose and Use a Durable Dry Ice Pack Sheet?
Direct answer
To select the right dry ice sheet, match the sheet weight to your product
weight using a 1:1 ratio, then adjust for seasonal temperatures, route complexity
and insulation quality. For example, a 4 pound shipment needs
about 4–5 pounds of dry ice sheets, with 35% extra in summer and 10% extra for
routes with multiple hand offs. Cut the sheets to fit and choose a
layout—top, surround or hybrid—based on transit time: top placement holds
temperatures for 24–36 hours, surround layouts for 36–60 hours and hybrid
packouts for up to 72 hours.
Expanded explanation
Sizing dry ice correctly prevents under cooling and avoids unnecessary weight.
Start with the baseline formula: Dry Ice Weight = Product Weight. Then
apply three factors:
• Season: Add 35% extra in summer, 15% in spring or fall and nothing in
winter.
• Route: Add 10% for multi hand off routes or 15% for “hot lanes” where
ambient temperatures are higher.
• Insulation: Subtract 10% if using premium insulation (e.g., thick foam
liners) and 25% if using vacuum insulated panels.
Once you have the total dry ice weight, choose a layout to optimize
sublimation. A top layout means placing sheets above the product; this
achieves sublimation rates of 8–12% per 24 hours and is ideal for short
shipments. A surround layout lines all sides of the cargo and
reduces sublimation to 6–9%, extending cooling to 36–60 hours.
A hybrid layout uses both top and side placement, resulting in rates of
5–8% and durations up to 72 hours. Experiment with these
strategies based on product sensitivity and transit time.
Sizing and layout strategies
| Product weight | Starting dry ice sheet weight (1:1) | Adjustments and what they mean |
| 4 lb | 4–5 lb | Add 35% in summer and 10% for multi hand offs; subtract 10% with premium insulation. Ensures 24–36 hour hold. |
| 8 lb | 8–10 lb | Add up to 15% for hot lanes; subtract 25% when using vacuum panels. Supports 36–60 hour shipments. |
| 12 lb | 12–15 lb | Add up to 35% for extreme heat; reduce 20–25% with premium insulation. Maintains frozen conditions for 48 hours or longer. |
User focused recommendations
Assess your product’s needs: Frozen goods require deep freeze sheets, while refrigerated goods may be better served by phase change materials (PCMs).
Apply the sizing formula: Multiply the product weight by one and adjust for season, route and insulation.
Select the right layout: Top placement suits quick deliveries; surround layouts for medium trips; hybrid packouts for maximum hold.
Leverage data and technology: Use historical shipping data and IoT sensors to monitor temperatures and refine dry ice usage. AI platforms can predict sublimation rates and suggest optimal quantities.
Reuse responsibly: Vent the sheet after use, then rehydrate and refreeze. Reusable sheets lower costs and reduce waste.
Case example: A Colorado seafood distributor adopted dry ice sheets to ship salmon fillets to Florida. By surrounding the fish with sheets and insulating with foam, the fillets arrived still frozen and free of condensation damage.
Safety and Regulatory Guidelines for Shipping with Dry Ice Sheets
Direct answer
Shipping dry ice requires compliance with FDA and DOT regulations, proper
ventilation and clear labeling. The U.S. FDA mandates that container closure
systems protect pharmaceutical products from contamination. The
Department of Transportation’s 49 CFR parts 173.196 and 173.199 require triple
packaging for diagnostic specimens (primary receptacle, secondary container and
outer packaging). Carriers like UPS and FedEx limit dry
ice weight and demand specific “Carbon Dioxide, Solid, UN1845” labels.
Detailed guidance
Ventilation and containers: Dry ice sublimates into carbon dioxide gas, so
never place it in airtight or glass containers that could rupture. Use
ventilated expanded polystyrene (EPS) foam boxes or vacuum insulated panels
inside sturdy cardboard cartons. Keep dry ice separate from
the product using liners or by placing sheets on top, allowing cold air to
circulate. UPS suggests using 5–10 pounds of dry ice
per 24 hours depending on insulation density and adding extra to cover
unexpected delays.
Labeling and documentation: All packages containing dry ice must display
the UN1845 label and indicate the net weight of dry ice. Air
travel limits passenger luggage to 2.5 kg of dry ice; cargo shipments require
Class 9 hazard labels and, in some cases, a Dangerous Goods declaration. USPS allows
dry ice only in domestic mail and requires packages to be marked with the
contents being cooled.
Training and safety: Anyone handling dry ice should wear insulated gloves and
goggles to prevent frostbite and eye injuries. Vent containers to allow gas
escape, use sturdy insulation and label packages clearly. Train staff on
CO₂ exposure hazards and emergency response procedures.
Regulatory highlights and best practices
| Regulation or guideline | Key requirements | Practical implications |
| FDA 21 CFR 211.94 (b) | Container closure systems must protect drugs from external factors. | Use leak proof secondary packaging and insulated outer boxes for pharmaceuticals. |
| DOT 49 CFR 173.196/173.199 | Triple packaging required for diagnostic specimens. | Place dry ice sheets outside the primary receptacle and ensure CO₂ can escape. |
| Carrier guidelines (UPS/FedEx) | Ventilated EPS containers; 5–10 lb dry ice per 24 h; proper labeling. | Leave vents open, avoid over taping and add extra dry ice for potential delays. |
Practical tips
Vent containers: Always allow gas to escape; never seal dry ice in glass or metal.
Separate products: Use liners or place sheets above goods to prevent direct contact and frost damage.
Wear protection: Gloves and goggles are essential to avoid frostbite and CO₂ exposure.
Label thoroughly: Include the UN1845 designation and net weight; follow carrier specific instructions for air, ground and postal shipments.
Train staff: Ensure everyone handling dry ice understands safety protocols and regulatory requirements.
Real world example: A diagnostic laboratory shipped blood samples from New York to California. By following DOT’s triple packaging rules, labeling the box with “Carbon Dioxide, Solid, UN1845” and leaving vents open, the samples arrived frozen and passed regulatory inspection.
Reusable Dry Ice Sheets vs Gel Packs vs PCM Sheets
Direct answer
Reusable dry ice sheets deliver deeper freezing (–21 °C) and longer hold times
than gel packs but require hazardous materials labeling; phase change material
(PCM) sheets provide reusable, stable cooling without hazard labels. Gel packs offer
temperatures around 0 °C to 5 °C and are best for refrigerated items.
Comparative analysis
Gel packs are commonly used for chilled products like salads or beverages but
can leak when punctured and usually aren’t reusable beyond a single cycle. USA dry ice
pack sheets maintain –21 °C for up to 24 hours per sheet and can be rehydrated
and refrozen multiple times. They sublimate without leaving liquid,
preventing soggy packaging and contamination. PCM sheets cover temperature
ranges from –20 °C to 5 °C and may last 48–72 hours; they are highly reusable
(often 500+ cycles) and avoid hazardous labeling.
Pros and cons table
| Refrigerant | Temperature range | Cooling duration | Leak risk | Reusability & sustainability | Best for |
| Gel packs | 0 °C to 5 °C | Up to 6 hours | Moderate; gel can leak when punctured | Limited; often single use and generate plastic waste | Chilled foods and beverages; not suitable for frozen goods. |
| Reusable dry ice sheets | –21 °C for up to 24 hours per sheet | 24–72 hours depending on layout | Very low; sublimation leaves no liquid | Yes; sheets can be rehydrated and refrozen multiple times | Frozen goods such as meat, seafood and biologics; requires hazard labeling and ventilation. |
| PCM sheets | –20 °C to 5 °C | 48–72 hours | Minimal; sealed PCMs do not leak | Highly reusable; 500+ cycles and often biodegradable | Refrigerated items like vaccines, produce or meal kits; avoids hazardous classifications. |
Recommendations
Choose dry ice sheets for shipments requiring deep freeze temperatures below –10 °C and durations up to 72 hours. Remember to comply with hazard labeling and ventilation.
Choose PCM sheets when you need stable 2–8 °C conditions, extended duration or enhanced sustainability; they reduce regulatory burdens and can be reused hundreds of times.
Stick with gel packs for very short chilled shipments or low value goods where leakage risk is acceptable and deep freeze isn’t required.
Consider hybrid packouts: Combining dry ice sheets with PCM or gel packs creates multi temperature zones and can extend cooling to 72 hours while reducing sublimation rates.
2025 Trends and Innovations in Cold Chain Packaging
Trend overview
The global cold chain market is expected to reach US$500 billion by
2025. Rapid growth in pharmaceuticals, biologics and online
grocery services is pushing logistics providers to adopt smarter, greener
technologies. Here are the key 2025 trends every shipper should know.
Latest developments at a glance
Eco friendly insulation: Manufacturers are developing bio based foams,
recyclable vacuum panels and compostable linings to reduce environmental impact
while improving thermal performance.
Real time temperature monitoring: IoT sensors and RFID tags embedded in
packaging provide real time data on temperature, humidity and location.
This allows proactive interventions if temperatures drift outside the target range.
AI driven logistics: Advanced algorithms analyze weather and route
conditions to predict dry ice sublimation rates, optimize quantities and plan
routes to avoid delays.
Hybrid packouts: Combining dry ice sheets with PCMs or gel packs creates
multi temperature environments within one shipment, extending cooling to 72 hours
and reducing sublimation.
Sustainability metrics: Businesses are tracking carbon footprints and waste
reduction. Reusable sheets and PCMs can cut waste by up to 60% and lower emissions
by 25%.
Market insights
Demand for reliable cold chain solutions is surging across the United States as
meal kit delivery, online grocery and biologic medicines become commonplace. As
carriers tighten regulations and consumers demand sustainability, more companies
are shifting from single use gel packs to reusable dry ice sheets and PCMs
. Real time monitoring and AI logistics are becoming the baseline
expectation for high value shipments. Staying competitive in this evolving
market means embracing smart, eco friendly packaging solutions.
Frequently Asked Questions
Q1: How long does a durable dry ice pack sheet stay cold?
A hydrated dry ice sheet maintains –21 °C for up to 24 hours. With a
surround or hybrid layout and good insulation, you can extend cooling to
36–72 hours.
Q2: Can I reuse dry ice sheets?
Yes. After the dry ice sublimates, vent the sheet outdoors, rehydrate it and
refreeze. Many sheets endure multiple freeze–thaw cycles, saving costs and
reducing waste.
Q3: Do dry ice sheets require a Dangerous Goods declaration?
Domestic shipments containing only dry ice generally do not require a full
Dangerous Goods declaration, but the package must be labeled “Carbon Dioxide,
Solid, UN1845” and list the net weight. International shipments or those
containing other hazardous materials may require additional documentation.
Q4: Are there safer alternatives to dry ice sheets?
Phase change material sheets provide stable 2–8 °C cooling, can be reused over
500 times and do not require hazardous labeling. They are ideal for
refrigerated goods but may not reach ultra cold temperatures required for deep
freeze products.
Q5: How should I dispose of used dry ice sheets?
Allow leftover dry ice to sublimate in a ventilated area away from people and
pets. Rehydrate and refreeze if reusable; otherwise, dispose according to local
recycling guidelines.
Summary and Recommendations
Dry ice pack sheets offer a flexible, reusable and mess free way to keep
temperature sensitive goods frozen during transit. Their three layer
construction and sealed cells deliver deep freeze temperatures without leaking
water. By following sizing formulas and layout strategies, you
can tailor the quantity and placement of sheets to your shipment’s weight,
transit duration and ambient conditions. Always comply with
FDA and DOT regulations, ventilate containers and label packages properly
. Compared with gel packs, dry ice sheets provide
colder temperatures and longer hold times, while phase change materials offer
reusable, hazard free cooling for refrigerated goods. Looking ahead to
2025, eco friendly insulation, IoT monitoring and AI logistics will continue
to transform the cold chain.
Actionable next steps
Identify your cooling needs: Determine whether your products need deep
freeze (<–10 °C), refrigerated (2–8 °C) or chilled (~0 °C) conditions.
Apply the sizing formula: Use the 1:1 dry ice to product weight rule and
adjust for season, route and insulation.
Select a layout: Choose top, surround or hybrid placement based on
transit duration.
Ensure compliance: Vent containers, label packages with UN1845 and net
weight, and train staff on safe handling.
Explore reusable options: Consider phase change material sheets or
hybrid packouts for greater sustainability and regulatory simplicity.
Leverage technology: Integrate IoT sensors and AI planning tools to
monitor temperature and optimize dry ice usage.
About Tempk
Tempk (Shanghai Huizhou Industrial Co., Ltd.) is a high tech company founded in
2011 that specializes in cold chain solutions for food and pharmaceuticals. With
state of the art R&D facilities and CNAS certified laboratories, Tempk develops
gel packs, dry ice sheets, insulated bags and containers for global clients. The company
focuses on eco friendly materials, offering reusable and recyclable products
that reduce waste and lower shipping costs. By partnering with
Tempk, you gain access to expertise in temperature control, product
customization and regulatory compliance. We invite you to consult our team for
tailored cold chain solutions that align with your business goals.
Call to action
Ready to optimize your cold chain? Contact the Tempk team for a free
consultation and discover how durable dry ice pack sheets and reusable PCM
solutions can protect your products and reduce costs.
