What’s the Maximum Dry Ice per Package Allowed?

The maximum dry ice per package allowed depends on mode and operator rules. In air cargo, it’s up to 200 kg per package; in passenger baggage, it’s 2.5 kg per person; USPS air caps a mailpiece at 5 lb. You still need vented packaging, UN1845 marking, and the right AWB text to pass acceptance. This article consolidates the latest 2025 compliance guidelines and practical cold chain advice.

Maximum Dry Ice per Package

Legal limits by mode with the maximum dry ice per package allowed for common scenarios
Packaging, labeling, and venting so handlers clear your shipment fast
A quick calculator approach to size dry ice without overpacking
Carrier variations and how to avoid rejections on specific lanes
2025 trends that influence safety, cost, and sustainability

What is the maximum dry ice per package allowed in 2025?

Short answer: Up to 200 kg per package for air cargo, 2.5 kg in passenger baggage, and ≤ 5 lb for USPS air. Ground has no single national cap; follow packaging, venting, and carrier weight/SOP limits. Always confirm operator variations before you ship. The same package can be legal on cargo but restricted on a passenger route.

Why it matters: A single wrong number on your label or AWB can hold freight at tender. Treat 200 kg as a global ceiling, not a guarantee. Your packaging must vent CO₂ and display UN1845, the proper shipping name, and net kg of dry ice on the box.

How do operator variations change the maximum dry ice per package allowed?

Airlines, express carriers, and postal services can set tighter limits. Common examples include lower per-package caps on some fleets, per-hold totals, and service-level restrictions. Plan your pack-out for the maximum dry ice per package allowed on that exact service and lane, not just the IATA headline rule.

Mode / Service	Limit (typical)	Key rule you must meet	What it means for you
Air cargo (UN1845)	200 kg / package	Venting + UN1845 + net kg + AWB text	Use validated shippers; print exact net kg
Passenger baggage	2.5 kg / passenger	Airline approval + venting + marking	Fine for short trips; not for bulk payloads
USPS air mailpiece	≤ 5 lb	Domestic air only + venting + label	Need more? Use surface/ground or cargo
Domestic ground (U.S.)	No national kg cap	Packaging + carrier SOP	Follow carrier weight limits (e.g., ≤ 150 lb/package)

Practical tips and quick wins

Print net kg, not “approx.” Align box, docs, and e-AWB values.
Never seal airtight. Venting is mandatory.
Overpacks: Marks must remain visible; never “hide” UN1845 and net kg.

Case in point: A biotech shipper cut spoilage by 40% after adding CO₂/temperature loggers and right-sizing per-package limits, then aligning labels and AWB entries with operator checklists.

How to calculate the maximum dry ice per package allowed for your lane?

Core idea: Match duration × sublimation rate × safety buffer. Use validated data for your container.

Quick formula:
Dry ice (lb) = (Transit hours ÷ 24) × daily sublimation rate × buffer (1.1–1.2)

Typical rates (24 h): Excellent foam shipper 4–6 lb; good plastic 6–8 lb; lined carton 8–10 lb.
Example: 48 h in a foam shipper at ~5–6 lb/day → 10–12 lb, plus 10–20 % buffer.
Reality check: Hot lanes, customs holds, and re-sorting increase consumption.

Planning input	Typical range	What to enter	Why it matters to you
Transit duration	+24–120 h	Add 1-day buffer	Delays are common
Daily loss (foam)	4–6 lb/24 h	Use worst-case	Prevent under-packing
Ambient risk	Mild / Hot	+10–20% in heat	Lane-specific safety
Net dry ice (kg)	Calculated	Put exact kg on box	Pass acceptance first time

Actionable tips

Short haul: Compact foam shipper with 2–6 kg often holds 24–36 h when pre-chilled.
Long haul: Combine dry ice with PCMs for smoother temperature control.
High value: Add CO₂ and temperature sensors; set alerts for trend breaks.

Labeling and packaging for the maximum dry ice per package allowed

Do this every time: UN1845, “Dry Ice” or “Carbon Dioxide, Solid,” net weight (kg) on the outer box, Class 9 label, vented design, and correct AWB line. No airtight seals. This is the fastest way to clear carrier acceptance with the maximum dry ice per package allowed.

Acceptance checklist:

Vented, robust outer + insulated inner.
UN1845 + proper name + net kg printed on box side.
Class 9 label visible; marks not covered by tape or overpack skins.
AWB shows UN1845, number of packages, and net kg per package.
Training up to date; use e-DGD where required.

Carrier differences: when the maximum dry ice per package allowed changes

Courier air: Many services cap packages below 200 kg, often 2.5–20 kg.
USPS: ≤ 5 lb by air; more must go ground.
UPS/FedEx/DHL: Follow IATA rules but check service-level SOPs.
Ground: Follow packaging and operator weight limits; no single national cap.

Pro move: Build a one-page SOP per lane listing the maximum dry ice per package allowed, AWB line format, and acceptance checklist.

2025 updates shaping the maximum dry ice per package allowed

What’s new: Digital acceptance and documentation are now standard. Expect e-DGD, lane-specific operator caps, and tighter overpack marking checks. Smart vent plugs and CO₂-aware packaging reduce pressure risk while cutting waste. Growing pharma and biologics demand favors validated foam/VIP kits and hybrid dry-ice + PCM designs.

Latest at a glance

e-DGD & checklists reduce paperwork errors.
Operator variations: 200 kg is the ceiling; check per-fleet limits.
Sustainability: CO₂ recovery and lighter shippers lower cost.

Market insight: Teams that validate pack-outs with data loggers often cut dry ice use by 10–20% while staying compliant.

FAQ: common compliance questions about the maximum dry ice per package allowed

Q1: What is the maximum dry ice per package allowed for air cargo?
Up to 200 kg per package, with venting, UN1845 marking, and correct AWB text. Operators may set lower limits.

Q2: How much can I carry in passenger baggage?
2.5 kg (5.5 lb) per passenger/package, airline approval required, and the container must vent.

Q3: What does USPS allow by air?
≤ 5 lb per mailpiece for domestic air; heavier amounts must go surface/ground or cargo.

Q4: Do I need a Shipper’s Declaration?
Not when dry ice cools non-dangerous goods; do include the UN1845 line on the AWB. If cooling dangerous goods, a declaration applies.

Q5: What happens if I exceed an operator’s cap?
Expect rejections, delays, or penalties. Always weigh and declare net kg correctly.

Summary & recommendations

Remember: The maximum dry ice per package allowed is 200 kg in air cargo, 2.5 kg in baggage, and 5 lb for USPS air. Use vented packaging, print UN1845 and net kg, and align AWB text to the booked service. Validate pack-outs with data to avoid over- or under-packing. Build lane-specific SOPs to ensure every shipment clears first time.

Next steps:

Confirm the carrier/service cap.
Use the calculator to size ice.
Print exact net kg on box and AWB.
Pilot with data loggers.
Review your training quarterly.

Internal links you can add

Dry Ice Labeling Guide (UN1845 & Class 9) → /knowledge/dry-ice-labeling-un1845
How to Build a 48-Hour Frozen Pack-Out → /knowledge/48h-frozen-packout
Validated Foam Shipper Sizing Calculator → /tools/shipper-sizing-calculator
Hybrid Cooling: Dry Ice + PCM → /knowledge/dry-ice-plus-pcm
AWB Examples for Dry Ice → /resources/dry-ice-awb-examples

Engagement boosters

Decision widget: “How much dry ice can I legally use?” (mode / carrier inputs)
Self-check quiz: “Can this package fly?” (5 yes/no checks)
Downloadable checklist: “Dry ice acceptance walk-through (2025).”

About Tempk

We help you ship frozen and refrigerated products safely and compliantly. Our validated foam/VIP shippers, dry-ice packs, and monitoring options keep lanes stable for 24–120 hours while meeting labeling and venting rules. We combine packaging science with hands-on lane design to shorten acceptance times and cut waste.

Call to action: Want a 10-minute pack-out review? Talk to a cold-chain specialist.