Shipping frozen products isn’t as simple as tossing them into a cooler. Dry ice packaging and dry ice packs allow you to keep vaccines, seafood and frozen treats at 78.5 °C ( 109.3 °F) without melting water, but they also come with safety rules and strict 2025 regulations. In this guide you’ll learn how to calculate the right amount of dry ice, pick the best insulated container, and discover when gel packs might be a better choice. You’ll also explore industry trends such as smart sensors and reusable systems that are shaping the future of cold chain logistics.
Understand what dry ice packaging is and how dry ice packs work, including sublimation and why they stay dry.
Follow a step by step process to package dry ice safely, from pre freezing products to labeling and venting.
Compare dry ice packs with gel ice packs and PCMs, so you can choose the right cooling method for your product.
Learn 2025 trends in dry ice packaging—smart sensors, blockchain, VIP insulation and sustainability.
Get answers to common questions about handling, disposal and regulatory compliance.
What Is Dry Ice Packaging and How Do Dry Ice Packs Work?
Dry ice is solid carbon dioxide. It forms when CO₂ is compressed and cooled, transitioning directly from a gas to a solid and back again without a liquid stage. At standard pressure dry ice is extremely cold ( 78.5 °C/ 109.3 °F). When it warms, it sublimates directly into gas, leaving no water residue. This property makes dry ice ideal for shipping frozen items because there’s no risk of soggy packaging or product damage.
A dry ice pack is a sealed pouch or block of dry ice used as a refrigerant. Unlike gel packs that thaw into liquid, dry ice packs maintain sub zero temperatures and eliminate melt water. Because dry ice absorbs heat as it sublimates, it can hold frozen temperatures for 24 72 hours depending on the amount used and insulation quality. A common rule is that 5–10 lbs (2.3–4.5 kg) of dry ice sublimate every 24 hours, so shippers must calculate the amount needed based on shipment size and duration.
Key safety rules for using dry ice packs
Dry ice is classified as a hazardous material, so proper handling and packaging are mandatory. The U.S. Department of Transportation (DOT) and the International Air Transport Association (IATA) restrict dry ice shipments and require labeling with “Dry Ice” or “Carbon Dioxide, Solid,” the UN number (UN 1845) and net weight. Because dry ice sublimates into CO₂ gas, airtight containers are prohibited—venting prevents pressure build up and explosion. Handlers should always wear insulated gloves and goggles to avoid frostbite, and packaging should prevent direct contact between dry ice and food.
Packaging materials and cooling duration
| Packaging material | Cooling duration | Ideal use | What it means for you |
| Insulated Styrofoam/EPS boxes | 24–48 hours | Short to medium distance shipments | Affordable and readily available but may need more dry ice during hot weather. |
| Thick corrugated boxes + liner | 12–36 hours | Larger loads or bulk shipments | Commonly used for seafood and frozen groceries; cost effective but less insulating. |
| Vacuum insulated panel (VIP) systems | 96–240 hours | High value or long haul shipments | VIP panels reduce dry ice consumption by 20–40 % and lower shipping weight. |
Practical tips and scenarios
Ventilation is critical: Always allow CO₂ gas to escape by leaving small gaps in the outer box. Never seal dry ice in plastic bags or glass containers.
Label clearly: Mark “Dry Ice, UN 1845” and net weight on the outer carton to comply with air and ground regulations. Use a Class 9 hazard label if shipping by air.
Separate product from dry ice: Place your goods in an inner box or sealed bag to prevent contact with dry ice. This protects delicate items like vaccines from freezer burn.
Case study: A pastry company reduced spoilage by 38 % by layering dry ice blocks at the bottom, sides and top of the shipment, creating a “sandwich” effect that eliminated warm pockets.
How to Calculate and Package Dry Ice Packs for Shipping
Correct packaging maximizes cold retention, ensures safety and meets regulatory requirements. Shipping with dry ice is not about guessing; it’s about planning. The following step by step process is adapted from the latest 2025 guidelines.
Pre freeze and prepare the product: Freeze your goods to at least 0 °F ( 18 °C) before packing. Dry ice maintains frozen status; it doesn’t freeze room temperature items. Check that your product can withstand ultra cold temperatures—if not, use phase change material (PCM) gel packs instead.
Choose a rigid outer container and insulated liner: Use a heavy duty corrugated box with a foam liner. For shipments beyond 72 hours, upgrade to VIP panels which provide 96–240 hours of protection. Ensure both the liner and outer box have vent holes to release CO₂ gas.
Calculate the amount of dry ice: A general guideline is 5–10 lbs (2.3–4.5 kg) of dry ice per 24 hours for every 10–15 lbs of product. Always add a 24 hour buffer for unexpected delays. Heavier insulation reduces the amount needed. The table below summarizes typical requirements:
| Shipment type | Dry ice (lbs per 24 h) | Duration | Temperature range | Practical meaning |
| Pharmaceuticals | 5–10 | 24–72 h | –20 °C to –70 °C | Ultra cold vaccines and biologics need larger amounts and thicker insulation. |
| Seafood | 1–2 | up to 24 h | –18 °C to –20 °C | A small quantity suffices; over freezing can damage texture. |
| Biotech samples | ~5 | 48 h | –20 °C to –50 °C | Enough dry ice keeps sensitive samples stable during transit. |
| Frozen foods | 2–3 | up to 24 h | –10 °C to –18 °C | Ideal for ice cream, meat or frozen meals; moderate amounts work well. |
Layer the dry ice around the product: Place blocks or pellets at the bottom of the liner, then insert your pre frozen product. Surround the sides and top with additional pellets to create a “sandwich” effect. Avoid direct contact by using a barrier or separate compartment.
Vent and close the container: Tape the outer box lightly. Leave small gaps or specialized vent holes so CO₂ gas can escape. Never use sealed plastic bags or steel drums because they can explode.
Label and document: Affix hazard labels and write “Dry Ice (UN 1845)” plus the net weight in kilograms. For air shipments, attach a Class 9 diamond hazard label and include the statement “UN 1845, Dry Ice, n × kg” on the air waybill.
Train staff and monitor: Provide training on handling dry ice (gloves, goggles, tongs) and include a temperature or IoT sensor in the package. Real time monitoring helps you respond to deviations during transit.
Selecting insulation and hybrid systems
Different insulation materials influence performance and cost. Expanded polystyrene (EPS) or polyurethane (PUR) foam coolers work for 24–48 h shipments. Thicker foam (1.5–2 inches) extends hold time and reduces dry ice consumption. VIP panels provide the highest efficiency, offering 96–240 h retention with minimal thickness. The initial cost is higher but lowers shipping weight and reduces carbon emissions.
Phase Change Material (PCM) packs maintain temperatures at 2–8 °C or –20 °C without the hazards of dry ice. They require preconditioning but can be reused and avoid hazardous material regulations. Hybrid systems combine dry ice and PCM to create multiple temperature zones; dry ice keeps the primary payload at –70 °C while PCM panels hold adjacent compartments between 2–8 °C. This approach reduces dry ice consumption and meets varied product requirements.
Practical guidance and actionable scenarios
Choose insulation based on transit time: Use EPS or PUR foam for domestic shipments up to two days, and VIP panels for international or high value shipments. Thicker insulation reduces the amount of dry ice needed, lowering weight and cost.
Opt for hybrid systems when shipping mixed goods: If your shipment includes items requiring different temperature ranges, pair dry ice with PCM packs to maintain separate zones.
Prepare a dry ice calculator: Use a simple decision tool that takes package weight, duration and insulation type to estimate dry ice needs. Including an interactive calculator on your website can boost user engagement and reduce customer error.
Real world example: A biotech company shipping cryogenic samples used VIP boxes with smart sensors, reducing dry ice usage by 30 % while maintaining stability over a 96 hour international flight. The sensors alerted staff of a minor temperature spike at customs, allowing intervention before sample degradation.
Dry Ice vs Gel Ice Packs: Which Cooling Method Fits Your 2025 Cold Chain?
Understanding the differences between dry ice and gel ice packs helps you match the cooling method to your product. Gel ice packs contain water, gel or PCM that freezes around 0 °C and provide moderate cooling (2–8 °C). Dry ice maintains ultra low temperatures ( 78.5 °C) but requires special handling and ventilation.
Comparing key features
| Feature | Gel ice packs | Dry ice packs | What it means for you |
| Temperature range | –20 °C to –30 °C; suitable for 2–8 °C when thawing | –78.5 °C | Dry ice keeps products frozen solid; gel packs keep them chilled but not frozen. |
| Handling safety | Easy to handle, non toxic and require no special protective gear | Requires gloves, ventilation and care to avoid frostbite | Gel packs are family friendly; dry ice demands trained handlers. |
| Environmental impact | Typically reusable and biodegradable | Releases CO₂ as it sublimes | Gel packs support sustainability initiatives; dry ice production repurposes industrial CO₂ but is single use. |
| Cost | Reusable and cost effective over time | Higher cost and often single use | Gel packs save money for recurring shipments; dry ice is economical for one off deep freeze needs. |
| Cooling duration | Consistent cooling up to 48 hours | 24–72 hours depending on quantity and insulation | Both require proper insulation; dry ice lasts longer but may overshoot for moderately cold goods. |
Choosing the right cooling method for different products
Gel ice packs are optimal for goods requiring 2–8 °C, such as fresh food, dairy, pharmaceuticals and e commerce meal kits. They provide consistent cooling for up to 48 hours without freezing the contents. Gel packs are also reusable and more environmentally friendly, making them ideal for grocery deliveries and recurring shipments.
Dry ice packs are indispensable when products must stay frozen solid, such as frozen meats, ice cream, biological samples and certain pharmaceutical products. They deliver ultra low temperatures and can hold frozen conditions for up to 72 hours. However, dry ice requires ventilation and hazardous materials labeling and is not reusable.
Hybrid solutions combine dry ice and gel packs or PCMs to create multiple temperature zones. For example, dry ice can maintain –70 °C for a vaccine vial, while a PCM pack keeps adjacent products between 2–8 °C. This approach reduces the amount of dry ice required and prevents over freezing of moderate temperature goods.
Practical tips
Assess your product’s temperature needs: Refrigeration (2–8 °C) usually calls for gel or PCM packs, while deep freezing (below –20 °C) requires dry ice.
Consider handling and safety: If your supply chain involves untrained staff or consumers, gel packs are safer and easier to handle.
Calculate total cost: Reusable gel packs may offer better long term value for frequent shipments, whereas dry ice is economical for occasional deep freeze shipments despite higher single use cost.
Case example: An online meal kit service switched from dry ice to PCM gel packs for deliveries within 48 hours. Customer satisfaction rose because food arrived chilled rather than frozen, and packaging waste decreased. For longer distance orders requiring frozen desserts, the company still uses dry ice but pairs it with VIP insulation to reduce consumption.
2025 Developments and Trends in Dry Ice Packaging and Cold Chain Logistics
The cold chain industry is rapidly evolving due to market growth, sustainability concerns and technological innovation. In 2025 the global cold chain market is projected to grow from USD 324.85 billion in 2024 to USD 862.33 billion by 2032, a compound annual growth rate (CAGR) of around 13 %. Here are the key trends that will shape dry ice packaging and cold chain logistics in 2025:
Smart sensors and IoT integration
Real time data loggers and IoT sensors are now standard in premium packaging. These devices monitor temperature, humidity and location, sending alerts when conditions deviate from setpoints. Mobile apps allow shippers to track shipments and intervene proactively, reducing spoilage and improving accountability. In 2025 expect deeper integration with predictive analytics and automated replenishment services.
Blockchain for traceability and compliance
Blockchain technology provides secure, tamper proof records of temperature data and custody events. Pharmaceutical shipments must prove compliance with Good Distribution Practices (GDP). Blockchain helps document every hand off and temperature reading, simplifying audits and enhancing trust.
Advanced insulation and VIP adoption
Vacuum insulated panels (VIPs) are gaining traction because they offer high thermal resistance with less bulk. VIPs enable 96–240 hour hold times while reducing shipping weight and carbon emissions. Eco friendly materials like recycled fiber composites are emerging as sustainable alternatives.
Reusable dry ice programs
Reusable systems combine advanced insulation with return logistics. Programs like Marken’s InfiniDI have shown that reusing dry ice packaging can cut dry ice usage by 50 % and reduce waste by up to 90 %. Such systems use smart tracking to ensure containers are returned and sanitized, appealing to pharmaceutical and biotech industries striving for sustainability.
Regulatory enhancements and carrier alignment
Regulators continue refining guidelines. IATA Packing Instruction 954 caps dry ice packages at 200 kg and mandates vented packaging. Many carriers now harmonize ground rules with air regulations, requiring proper labeling even for ground shipments. U.S. postal regulations updated in 2025 allow up to 5 lbs of dry ice in domestic air mail while still prohibiting international mail. Carriers emphasize “no sealed bags” and clearer hazard label placement.
Market and product diversification
The cold chain landscape is changing due to new products. Demand for plant based protein, gluten free and organic foods is booming. These products require specialized temperature control and are often shipped by small to medium sized businesses seeking logistics partners with innovation and network reach. At the same time, aging cold storage facilities are being upgraded with automation, sustainability improvements and new refrigerants to meet stricter environmental regulations.
Visibility and software investments
Higher quality insights are critical for refrigerated products, so companies are investing in software that improves supply chain visibility. Continuous data allows shippers to handle disruptions, track location and monitor temperature. By integrating sensors with logistics management platforms, businesses can make data driven decisions and reduce risk.
Distribution and facility upgrades
Cold chain facilities are being strategically located closer to production areas and consumers. Upgraded infrastructure includes automation, energy efficient systems and advanced monitoring. Market resilience is increasing despite geopolitical disruptions, and the industry is preparing for volatility in capacity and transit times.
Frequently Asked Questions
Q1: How long can dry ice maintain cooling during transport?
Dry ice typically lasts 24–48 hours, and in well insulated containers it can maintain sub zero temperatures up to 72 hours. The exact duration depends on the quantity of dry ice, insulation type and ambient conditions. Always add a 24 hour buffer to accommodate potential delays.
Q2: Is dry ice safe for food transportation?
Yes. Dry ice is used widely for shipping frozen food, seafood and pharmaceuticals. However, you must prevent direct contact between dry ice and food to avoid freezer burn and ensure packages are vented to allow CO₂ gas to escape.
Q3: How much dry ice should I use per pound of product?
A common guideline is 5–10 lbs of dry ice per 24 hours for every 10–15 lbs of product. Adjust the amount for insulation quality and add extra dry ice for longer transit times.
Q4: Do I need a special declaration when shipping only dry ice?
Generally no. When dry ice is the sole hazardous material, a shipper’s declaration isn’t required. You still need to label the package with “Dry Ice” or “Carbon Dioxide, Solid,” UN 1845 and net weight, and attach a Class 9 hazard label for air shipments. Check carrier requirements because some carriers require declarations when other dangerous goods are included.
Q5: How should I dispose of dry ice after delivery?
Allow dry ice to sublimate in a well ventilated area away from children and pets. Do not place it in sinks or waste systems because the extreme cold may damage fixtures. Follow local hazardous waste guidelines if they apply.
Summary and Recommendations
Shipping frozen or ultra cold goods requires more than a cooler and good intentions. Dry ice packaging offers unmatched freezing capability but comes with strict handling and regulatory requirements. To ship confidently:
Plan ahead: Pre freeze products, select appropriate insulation and calculate the right amount of dry ice using the 5–10 lbs per 24 hours rule.
Package properly: Layer dry ice around the product, leave venting channels and label with “Dry Ice, UN 1845” and net weight.
Choose the right cooling method: Use gel or PCM packs for refrigeration (2–8 °C) and dry ice for frozen or ultra cold shipments. Hybrid systems offer flexibility for mixed loads.
Stay informed about 2025 trends: Embrace smart sensors, blockchain, reusable systems and VIP insulation to improve performance and sustainability.
By following these guidelines you’ll reduce spoilage, comply with regulations and deliver products safely. If you’re unsure which solution is best, consult a cold chain specialist.
About Tempk
Tempk is a leader in innovative cold chain packaging. We design and manufacture dry ice packaging, gel ice packs, phase change materials and insulated containers to help businesses maintain required temperatures during shipping. Our research and development team focuses on reusable, eco friendly solutions, and our packaging is validated for pharmaceutical, food and biotech applications. With expertise in regulatory compliance and real time monitoring, we provide tailored cold chain solutions that balance performance, sustainability and cost.
Action Call: Contact the Tempk team for a consultation on how to optimize your dry ice packaging and reduce waste. We can help you select the right insulation, calculate dry ice needs and integrate smart sensors for total visibility.
