Nearby Dry Ice Pack Sheet: 2025 Guide for Ultra Cold Shipping & Safe Use
Looking for a nearby dry ice pack sheet? You’re in the right place. This article explains what a dry ice pack sheet is, how it works and why it matters for your cold chain. A dry ice pack sheet is a flexible blanket filled with pockets of solid carbon dioxide that wraps around cargo and maintains temperatures near −78.5 °C for up to 72 hours. Unlike gel packs that melt and create soggy boxes, dry ice sublimates directly into gas, leaving no mess. By the end, you’ll know how to size, pack and handle these sheets safely, understand when to choose them over blocks or gels, and see how 2025 market trends and regulations affect your decisions.
What is a dry ice pack sheet and how does it differ from gel packs?
How do you size, hydrate and pack a dry ice sheet for your shipment?
What safety and regulatory rules apply when using dry ice pack sheets?
When should you use sheets, blocks or gel packs and what are the pros and cons?
What 2025 trends and innovations shape the use of dry ice pack sheets?
Frequently asked questions and next step recommendations.
What is a Dry Ice Pack Sheet and Why Is It Different from Regular Ice Packs?
A dry ice pack sheet is a multi cell blanket made of super absorbent polymer pockets loaded with solid carbon dioxide (CO₂). When hydrated and frozen, the sheet becomes rigid enough to wrap around irregular cargo like vials and meal kits while remaining thin and flexible. Dry ice sublimates (turns from solid to gas) at about −78.5 °C (−109.3 °F), delivering ultra cold temperatures for up to 72 hours without leaving water behind. Gel packs, on the other hand, operate around 0–4 °C and last only 6–12 hours. Because dry ice sheets vent gas instead of melting, you avoid puddles and reduce contamination risk.
Dry Ice vs. Gel Packs: Key Properties & Advantages
The table below compares dry ice sheets with gel packs and highlights what that means for you:
| Feature | Dry Ice Pack Sheets | Traditional Gel Packs | What This Means for You |
| Temperature range | ~–78.5 °C | 0–4 °C | Dry ice sheets enable ultra cold shipments; gels only cover chilled goods. |
| Cooling duration | Up to 72 hours | 6–12 hours | Dry ice reduces the need for refrigerant replenishment over long routes. |
| Residue | None (sublimates to gas) | Water (melts) | No risk of soggy packaging or label damage. |
| Reusability | Single use | Often reusable | Dry ice costs more per trip but provides ultra cold performance. |
| Best use cases | Pharmaceuticals, biologics, frozen foods | Chilled foods and beverages | Choose dry ice for products that must remain below freezing. |
Why it matters: Gel packs melt into water and saturate labels, while dry ice sheets vent harmless gas and avoid moisture. For shipments requiring sub zero temperatures—such as vaccines, biologics or frozen seafood—dry ice sheets are the preferred solution. Gel packs are better suited for chilled produce or beverages where freezing is undesirable.
How Sublimation Delivers Ultra Cold Cooling
When dry ice sublimates, it absorbs about 571 kJ of heat per kilogram, drawing energy from the surrounding product and container. This endothermic reaction acts like a cold blanket: as CO₂ pockets convert to gas, they pull heat away evenly and prevent warm corners. By wrapping around cargo, dry ice sheets reduce dead air spaces and provide more uniform temperatures than loose pellets, which can shift and leave hot spots. In contrast, gel packs gradually release stored cold at a higher temperature range and cannot absorb as much heat.
Real world case: A biotechnology company shipped mRNA vaccines using flexible dry ice sheets that wrapped around each vial. The sheets maintained –75 °C for 72 hours despite ambient temperatures of 25 °C, and the vials arrived dry and uncontaminated. This consistent cooling prevented potency loss and simplified disposal.
How to Size, Hydrate and Pack a Dry Ice Pack Sheet
Correct sizing and preparation ensure your dry ice sheet keeps cargo ultra cold without wasting refrigerant. The general rule is to match the weight of dry ice to the weight of your product, though longer journeys may require up to 2 kg of dry ice per kilogram of payload. Thickness matters too: sheets come in 12 mm, 18 mm and 24 mm options, each suited for different transit times.
Sizing Guide by Duration
| Transit Duration | Recommended Sheet Thickness | Approx. Dry Ice per kg of Product | Meaning for You |
| Up to 24 hours | 12 mm sheet | 1 kg dry ice/kg product | Ideal for overnight shipments; keeps goods below –20 °C for one day. |
| 24–48 hours | 18 mm sheet or two 12 mm layers | 1–1.5 kg/kg product | Suitable for two day deliveries; layering provides redundant cooling. |
| 48–72 hours | 24 mm sheet or three 12 mm layers | 2 kg/kg product | Essential for extended transit; maintains –75 °C for three days. |
Step by Step Preparation and Packing
Hydrate and freeze the sheet – Soak your dry ice sheet in water until the polymer cells are fully hydrated, then freeze it flat overnight. This creates a matrix that evenly encapsulates CO₂.
Pre chill your cargo and container – Refrigerate both product and insulated box before adding dry ice to prevent wasting energy on cooling the container.
Layer strategically – Use the “dry ice sandwich” method: place a sheet at the bottom, the product in the middle and another sheet on top. For irregular shapes, wrap the sheet completely around the cargo to ensure uniform contact.
Allow ventilation – Dry ice releases CO₂ gas as it sublimates. Choose vented containers or drill holes to prevent pressure build up. Never seal dry ice sheets in airtight bags.
Avoid direct contact – Use dividers or padding to separate dry ice sheets from fragile items like glass vials or delicate foods.
Track weight and time – For shipments longer than 48 hours, increase dry ice mass by about 50 %. Monitor hold time and adjust based on ambient temperature.
Case study: A seafood exporter shipped frozen fish across continents using a 24 mm dry ice sheet. By matching dry ice weight to the fish at a 1:1 ratio and using vacuum insulated panels, the shipment maintained –40 °C for 60 hours. The flexible sheet conformed to the fish’s shape, preventing temperature spikes and condensation.
Safety and Regulatory Considerations
Dry ice is extremely cold and classified as a hazardous material. Proper handling and compliance protect you and your customers.
Personal Safety
Wear protective gear: Use insulated gloves and safety goggles to avoid frostbite; never handle dry ice with bare hands.
Use tongs or tools: Prevent direct contact and protect surfaces from freezing damage.
Ventilate during storage and disposal: Sublimation releases CO₂ gas that can displace oxygen. Store and dispose of sheets in well ventilated areas.
Educate end users: Label packages clearly to warn about dry ice and provide safe disposal instructions. Never store dry ice in airtight containers; gas buildup can cause explosions.
Avoid drains and plumbing: Don’t place dry ice in sinks or toilets; extreme cold can damage fixtures.
Regulatory Compliance
Hazard classification: Dry ice (UN 1845) is a Class 9 hazardous material. Packages must display the proper shipping name, UN number and net weight on the same side as the hazard label.
Weight limits: In the United States, shipments containing more than 5.5 lb (2.5 kg) of dry ice must comply with Title 49 of the Code of Federal Regulations (49 CFR) and International Air Transport Association (IATA) rules. For air travel, each passenger may carry up to 2.5 kg of dry ice in a vented container.
Labeling and documentation: Provide clear documentation of dry ice weight and ensure venting instructions are visible on the package. Regulatory changes in 2025 emphasize real time monitoring and validated packaging.
Safety Tips for Lunch Boxes and Daily Use
Dry ice pack sheets can also keep meals cold when a refrigerator isn’t available. A dry ice pack sheet lunch box is an insulated container paired with a hydrated pack sheet that keeps food below 40 °F (4 °C) for hours. Pack sheets freeze flat and save space, while vented lids prevent pressure build up. For children and offices, use water based or PCM pack sheets targeting 32 °F to 50 °F—these are safer and reusable. Follow these steps:
Pre chill the box for 10–15 minutes.
Condition the pack sheet by hydrating and freezing overnight.
Add a barrier layer such as a towel to avoid wet lids.
Load food compactly and fill air gaps.
Top with the pack sheet—cold air sinks.
If using true dry ice, ensure the container is vented and labeled “Dry Ice / UN1845”.
Consume perishable foods within 2 hours if ambient or keep below 40 °F.
Hold time planning: Most lunch box setups maintain safe temperatures for 4–8 hours indoors. Adding true dry ice extends cold time for frozen desserts or flights; the Federal Aviation Administration limits each passenger to 2.5 kg (5.5 lb) of dry ice. To size a lunch box, start with one standard pack sheet per 3–4 lb of food for moderate conditions, and double it or add a small dry ice block for hot commutes.
When Should You Choose Dry Ice Sheets, Blocks or Gel Packs?
Choosing between dry ice blocks, pellets, sheets and gel packs depends on duration, payload size, temperature requirements and handling capacity. A large dry ice sheet excels when you need sustained ultra cold conditions for 24–72 hours and want flexible packaging. Blocks offer longer duration due to larger mass but are heavy and harder to handle. Gel packs are ideal for chilled goods at 0–8 °C, reusable and non hazardous.
Decision Criteria
Shipment duration – Use sheets for next day or two day deliveries; choose blocks for multi day or bulk shipments.
Payload size – Sheets conform to irregular shapes and maximize contact; blocks are better for pallets or large crates.
Temperature sensitivity – Dry ice (–78.5 °C) is needed for frozen goods like biologics, vaccines and ice cream; gel packs and PCMs maintain 2–8 °C for chilled items.
Handling and regulations – Dry ice requires special handling, labeling and adherence to weight limits. Gel packs are safer and simpler for untrained customers.
Environmental impact – Gel packs can be reused or recycled; dry ice releases CO₂ gas and is single use. Some hybrid systems pair gel packs with reduced dry ice to cut emissions.
Pros and Cons by Refrigerant Type
| Refrigerant Type | Pros | Cons | Best For |
| Dry ice blocks | Extended cooling duration; can be cut to custom size | Heavy and bulky; harder to handle; require more storage space | Multi day shipments of large payloads (e.g., pallets of frozen food or bulk medical supplies). |
| Dry ice pack sheets | Space efficient, flexible; lightweight; pre measured sizes simplify packing | Shorter duration (24–72 h); must be sealed properly to avoid moisture release | Next day shipments, small biotech samples, meal kits and irregularly shaped items. |
| Gel packs/PCMs | Ideal for chilled goods; reusable; non hazardous | Cannot reach ultra cold temperatures; produce meltwater | Fresh produce, pharmaceuticals requiring 2–8 °C, and products that must not freeze. |
Sizing Rules of Thumb
Overnight shipments – Pack half the weight of the payload in dry ice blocks; equal weights of dry ice and product provide up to 48 hours.
Two day shipments – Use equal weight of dry ice to product (1:1 ratio) to keep the product frozen.
Three day shipments – Plan for 1.5 times the product weight in dry ice.
Hybrid pack outs – Combining gel packs and dry ice can slow sublimation and prolong hold time.
2025 Trends and Innovations Shaping Dry Ice Packaging
Market Growth and Drivers
The cold chain packaging market is booming. Research and Markets estimates the market size at USD 32.29 billion in 2025 and projects it to reach USD 48.93 billion by 2030, growing at an 8.67 % compound annual growth rate (CAGR). Several trends fuel this growth:
Biologics and cell/gene therapy logistics – Nearly half of new pharmaceuticals require temperature control. Many advanced therapies demand cryogenic conditions, driving demand for ultra cold packaging.
E commerce grocery expansion – Online grocery and meal kit deliveries are increasing, requiring lightweight, space efficient refrigeration for last mile logistics.
Global vaccine programmes – Organizations like Gavi and WHO standardize performance baselines for vaccine transport, pushing suppliers to design rugged, rapidly deployable solutions.
Regulations and IoT monitoring – U.S. FDA 21 CFR 600.15 and European packaging regulations mandate validated temperature controlled packaging and encourage real time monitoring.
Sustainability – Environmental, Social and Governance (ESG) targets accelerate adoption of reusable and bio based materials.
Technological Innovations
Smart sensors & IoT – Dry ice containers now integrate sensors that track temperature, humidity and location, sending real time alerts when thresholds are breached. This data helps optimize pack configurations based on weather and route conditions.
AI driven packing algorithms – Meal kit companies use AI to adjust the number and type of sheets based on external conditions, reducing waste and improving customer experience.
Sustainable materials – Manufacturers experiment with biodegradable insulation and recyclable liners to complement dry ice, reducing plastic waste.
Reusable passive shippers – Hybrid systems combine vacuum insulated panels with replaceable dry ice cartridges, delivering high performance while cutting waste.
Market Trends Summary
| Trend | Description | Practical Impact |
| Boom in biologics logistics | Higher volumes of temperature sensitive biologics require ultra cold packaging solutions | Drives demand for dry ice sheets and cryogenic shippers. |
| E commerce grocery surge | Meal kits and frozen foods delivered direct to consumers need space efficient refrigeration | Increases adoption of flexible dry ice sheets for last mile deliveries. |
| Global vaccine initiatives | Standardized performance baselines and rugged designs for remote clinics | Emphasizes reliability and extended duration of dry ice sheets. |
| Regulatory pressure | Stricter FDA and EU regulations demand validated, traceable packaging | Encourages use of smart sensors and compliance labeling. |
| Sustainability & ESG | Companies shift toward reusable and bio based packaging | Sparks innovation in recyclable liners and hybrid systems. |
Frequently Asked Questions
Q1: Why choose a large dry ice pack sheet instead of smaller sheets or pellets?
Large sheets provide better surface contact and reduce air gaps, delivering more uniform cooling and fewer hot spots. They are easier to handle than loose pellets, which can blow away during packing and cause uneven distribution.
Q2: How much dry ice should I use for a 10 kg shipment?
A good rule of thumb is to start with the same weight of dry ice as your product—10 kg of dry ice for a 10 kg payload. For shipments longer than 48 hours, increase to 15 kg and layer multiple sheets.
Q3: Can dry ice damage my products?
Dry ice is extremely cold and can freeze items not designed to withstand sub zero temperatures. Never ship live seafood, flowers or products sensitive to freezing with dry ice. Always use dividers or insulation between dry ice and fragile products.
Q4: Are dry ice sheets reusable?
No. Dry ice sublimates completely and cannot be reused. Some packages combine reusable shells with replaceable dry ice cartridges for sustainability, but the dry ice itself is single use.
Q5: How do I dispose of a dry ice sheet?
Place leftover dry ice in a well ventilated area and allow it to sublimate. Do not dispose of it in sinks or toilets, and keep it away from children and pets.
Summary & Recommendations
Key Takeaways:
Dry ice pack sheets are flexible blankets filled with CO₂ pockets that deliver ultra cold temperatures (~–78.5 °C) for up to 72 hours without leaving residue.
Sheets provide better contact and uniform cooling than pellets or blocks and avoid the mess associated with gel packs.
Correct sizing and preparation are crucial: match dry ice weight to product weight, choose sheet thickness based on transit duration, and pre chill your cargo.
Handle dry ice with care—use protective gear, vent containers and follow regulatory limits. For flights, the limit is 2.5 kg per traveler.
Choose sheets, blocks or gels based on shipment duration, payload size and temperature requirements; hybrid pack outs can extend hold time and reduce costs.
The cold chain packaging market is growing rapidly, driven by biologics logistics, e commerce groceries, global vaccines, stricter regulations and sustainability goals.
Action Plan:
Assess your shipment requirements: Determine duration, temperature range and payload size. Use the sizing tables above to estimate dry ice mass.
Choose the right refrigerant: Use dry ice sheets for ultra cold loads (vaccines, biologics, frozen seafood), gel packs for chilled goods, and blocks for multi day or bulk shipments.
Prepare and pack correctly: Hydrate and freeze sheets, pre chill cargo, layer strategically and vent containers. Always wear protective gear and label packages.
Monitor performance: Use IoT sensors or temperature loggers to track internal temperature and adjust pack outs for future shipments.
Adopt sustainable practices: Consider hybrid pack outs, reusable shells and recyclable insulation to reduce waste and meet ESG goals.
About Tempk
We are Tempk, a manufacturer specialising in cold chain packaging solutions. Our dry ice pack sheets feature multi ply construction, super absorbent polymer pockets and robust outer films that withstand handling and provide consistent ultra cold temperatures. We invest in research and development to create eco friendly packaging options, including recyclable liners and reusable passive systems. Our R&D centre collaborates with customers to validate shipping lanes and design pack outs that comply with 2025 regulations while reducing logistics costs. Whether you ship vaccines, seafood or meal kits, we offer tailored solutions, technical support and testing resources to keep your products safe and compliant.
Call to Action: Ready to optimize your cold chain? Contact Tempk’s experts to design the ideal dry ice pack sheet solution for your shipment. Let’s keep your products safe, compliant and sustainable.
