Intro: If you’re asking how to pack with dry ice for shipping, here’s the short answer: pre‑freeze products, use a vented insulated shipper, surround the payload with dry ice, and mark UN 1845 with net kilograms and a Class 9 label for air. Plan roughly 5–10 lb per 24 hours plus a buffer to ride out delays.
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Dry‑ice sizing that fits your lane, with a 5–10 lb per day estimator (long‑tail: dry ice amount per 24 hours)
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Labeling and documents: UN 1845, net kg, Class 9, and AWB text for air (long‑tail: IATA PI 954 checklist)
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Packaging choices that cut thaw claims (long‑tail: VIP vs foam insulated shipper)
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Operator tips that boost acceptance and reduce returns (long‑tail: vented packaging dry ice)
How to pack with dry ice for shipping step‑by‑step?
Direct answer: Pre‑freeze to 0 °F (–18 °C), use a rigid outer box with an EPS/PU/VIP liner, keep vents open, place dry ice around (not just under) the payload, and mark “Dry Ice/Carbon dioxide, solid,” UN 1845, and net kg; add Class 9 for air. Size 5–10 lb per day of transit and add a 24‑hour buffer.
Why this works: Dry ice becomes CO₂ gas; your packaging must vent to avoid pressure build. Air shipments follow IATA PI 954 (vented packaging, AWB entries, ≤200 kg/package, Class 9). Ground (U.S.) still requires UN 1845 proper name and net kg on the carton, and the packaging must release gas. Carriers often align with IATA for smoother acceptance.
How much dry ice per day for frozen shipments?
Plan 5–10 lb per 24 hours in a well‑insulated shipper, then add margin for heat and delays. Better insulation (thick EPS, PUR, or VIP) lowers daily burn‑off; fuller loads reduce warm air pockets. Convert to kilograms for labels (kg = lb × 0.4536).
| Sizing Snapshot | Baseline (lb) | With Buffer (lb) | What it means for you |
|---|---|---|---|
| 24 h, standard EPS | ~8 | ~10 | Weekend risk? Round to 12 lb. |
| 48 h, thick EPS | ~16 | ~20 | Fewer hot spots; steadier temps. |
| 72 h, VIP | ~22 | ~26 | VIP cuts total ice mass. |
Practical tips and quick wins
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Hot two‑day route: Upgrade to 1.5–2 in insulation or VIP; then add 20% extra dry ice.
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Food contact: Use a barrier so ice never touches food directly; avoid sealed plastic bags for the dry ice.
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Placement: “Sandwich” the payload—base blocks + sides + top pellets—to eliminate warm pockets.
Real‑world case: A DTC pastry brand switched from pellets‑only to blocks at the base plus pellets on the sides/top and added a 20% summer buffer; “soft deliveries” fell 38% and on‑temp arrivals jumped.
How to pack with dry ice for shipping: labels & documents?
Direct answer: Mark “Dry Ice/Carbon dioxide, solid,” UN 1845, net dry‑ice mass in kilograms, and apply the Class 9 label for air. On the airway bill add: “UN 1845, Dry Ice, n × kg.” IATA PI 954 caps 200 kg/package and requires vented packaging.
Expanded guidance: U.S. ground (HMR/PHMSA) still requires proper name, UN 1845, net kg, and venting; a Class 9 label isn’t mandated by HMR, though carriers may harmonize to IATA. FedEx job aids also specify readable minimum type sizes and 100×100 mm Class 9 diamonds; affix labels on the outer box, not inside sleeves.
Copy‑ready templates (keep with your SOP)
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AWB text:
UN 1845, Dry Ice, __ packages × __ kg -
Carton marks (air): Proper name, UN 1845, net kg, Class 9; shipper/consignee addresses.
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Carton marks (U.S. ground): Proper name, UN 1845, net kg; vented package (no airtight systems).
Which packaging helps you pack with dry ice for shipping efficiently?
Direct answer: Use a rigid corrugated outer with an insulated insert (EPS/PUR for 24–72 h; VIP for longer or riskier lanes). Never make the system airtight—CO₂ must escape.
Expanded: EPS is cost‑effective for 1–2 days; thicker EPS/PUR extends hold time; VIP achieves multi‑day performance with less refrigerant and weight, reducing claims and volumetric charges—ideal for international or hot lanes.
VIP vs foam: when does “premium” pay back?
Details: VIP systems deliver 96–240+ hours performance at lower dry‑ice mass. If your lanes face delays or the payload is high‑value, VIP often lowers total landed cost through weight savings and fewer reships.
| Packaging | Typical thickness | Typical duration | What it means for you |
|---|---|---|---|
| EPS (foam) | 1–1.5 in | 24–48 h | Cheapest; add buffer in heat. |
| Thick EPS / PUR | 1.5–2 in | 48–72 h | Longer hold; less ice mass. |
| VIP panels | 0.4–0.8 in | 96–240 h | Thinnest walls; best stability. |
How to pack with dry ice for shipping across carriers?
Direct answer: For FedEx/UPS air, follow IATA PI 954 (vented packaging, UN 1845, Class 9, AWB text). USPS allows ≤5 lb dry ice in domestic air mail with specific packaging rules; international mail with dry ice is prohibited.
Expanded: Expect acceptance checks at counters. Getting AWB text and net kg perfect speeds acceptance. Many integrators harmonize ground handling to the air standard to reduce errors.
Cold‑chain compliance beyond how to pack with dry ice for shipping
Direct answer: Document your temperature controls, train staff, and retain records to satisfy FSMA Sanitary Transportation requirements. Define arrival targets (e.g., 0 °F for frozen foods), sizing logic, and verification (data loggers or arrival checks).
Simple checklist: Procedures; training (PPE, venting, labeling); records (lane plans, logger files, corrective actions). Build this into your SOP and audits.
2025 developments and trends in dry‑ice shipping
Trend overview: Carriers tightened acceptance against PI 954 checklists (e.g., explicit 200 kg/package and venting). USPS updated Publication 52 in 2025; VIP and reusables are rising to reduce refrigerant weight and claims. Expect faster counter acceptance when labels and AWB entries are exact.
Latest progress at a glance
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VIP adoption accelerates: Higher hold times with less ice reduce cost and damage.
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Reusable programs expand: Lower waste and stable thermal profiles for recurring lanes.
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Job‑aid clarity improves: Label sizes, text heights, and “no sealed bags” called out plainly.
Market insight: Cold‑chain packaging demand keeps growing with DTC frozen foods and biologics. Upgrading to thicker liners or VIP plus smarter sizing typically cuts refunds and re‑ships—an ROI many shippers now measure in weeks, not quarters.
FAQ
Q1: Do I need a Shipper’s Declaration if dry ice is the only DG?
Usually no when contents are non‑DG; you still need UN 1845, net kg, Class 9 (air), and correct AWB text. Verify operator variations.
Q2: How much dry ice should I plan per day?
Start with 5–10 lb per 24 hours, then add a 24‑hour buffer for delays; better insulation reduces the amount.
Q3: What size should the Class 9 label be?
Minimum 100 × 100 mm; keep borders clear and don’t write inside the diamond.
Q4: Any carrier‑specific gotchas?
USPS air caps at ≤5 lb per mailpiece and bans international dry‑ice mail. FedEx/UPS enforce PI 954 acceptance details at counters.
Q5: What mistakes trigger delays?
Airtight packages, missing net kg, marking pounds instead of kilograms, thin insulation, and skipping top/side coverage.
Summary & recommendations
Remember: How to pack with dry ice for shipping comes down to vented insulated packaging, side/top coverage, and correct UN 1845 + net kg marking (Class 9 for air). Plan 5–10 lb/day plus buffer; upgrade insulation on hot or long lanes; and keep FSMA documentation tidy.
Next steps: Map your hottest week and transit hours; choose EPS/PUR ≥1.5 in or VIP; compute ice with the estimator; print your AWB/carton templates; run a test with a logger; roll into SOPs site‑wide. CTA: Start a lane‑specific packout design with Tempk today.
About Tempk
We engineer temperature‑controlled packaging—EPS, PUR, and VIP systems validated for PI 954—that balance compliance and cost. Our packout science, data loggers, and lane‑tuned sizing help you ship colder with less weight, cut claims, and speed airline acceptance. Clients routinely see fewer reships and faster counter clearance after deploying our SOPs. Let’s design your next packout.
