Shipping perishable goods across distances is challenging, especially when you need to keep products at sub zero temperatures. A portable dry ice pack is a reusable, dry type cooling unit that uses a polymer gel and dry ice technology to maintain low temperatures without messy meltwater. In 2025 the cold chain industry relies on them more than ever because they are lightweight, environmentally friendly and efficient This article explains how these packs work, compares them with other cooling options and shares best practices to help you choose the right solution.
What is a portable dry ice pack and how is it made?
How do portable dry ice packs work and why are they effective for shipping?
Where can you use portable dry ice packs in 2025?
What are the advantages and disadvantages compared with gel packs and water packs?
How do you prepare and use portable dry ice packs safely?
What are the latest trends in portable dry ice pack technology and market dynamics?
Frequently asked questions about dry ice packs and cold chain logistics
What is a portable dry ice pack and why does it matter in 2025?
A portable dry ice pack is a sealed pouch containing a super absorbent polymer (SAP) layer, non woven fabric and a leak proof film designed to hold water and freeze into a gel that remains flexible Once frozen, the pack behaves like dry ice, releasing cold energy as carbon dioxide sublimates, yet without the handling risks of pure dry ice. It provides long lasting cooling and fits neatly inside insulated boxes.
How portable dry ice packs are made
Portable dry ice packs have a layered structure:
| Component | Description | Practical benefit |
| Outer layer | Made of polyethylene (PE) film or water permeable non woven fabric | Provides strength and permeability so the pack can absorb watereuropeanbusinessreview.com |
| Super absorbent polymer (SAP) | Rapidly absorbs water and forms a stable gel | Holds a large volume of water, ensuring prolonged coolingeuropeanbusinessreview.com |
| Leak proof film | Composite film layer sealing the pack | Prevents leaks during transport and improves safetyeuropeanbusinessreview.com |
Manufacturers soak the pack in water for about 15 minutes. The SAP swells into a gel, then the pack is frozen to create a dry, solid block. Because the polymer retains some flexibility after freezing, the pack can conform closely to products without cracking This flexibility reduces air gaps and improves cooling efficiency compared with rigid gel packs.
Why does it matter in 2025?
The cold chain industry faces rising demand for ultra cold logistics amid supply pressures. The global dry ice market grew around 5 % per year, but CO₂ supply increased only 0.5 % annually. Prices occasionally surged 300 % during shortages. At the same time, consumers expect sustainable packaging and regulatory compliance. Portable dry ice packs meet these challenges because they use non toxic SAP and water, reducing environmental riskseuropeanbusinessreview.com and allowing companies to maintain cold temperatures without relying solely on volatile dry ice supplies. They are also lightweight and compact, saving transportation space
How does a portable dry ice pack work?
Portable dry ice packs rely on phase change—freezing and sublimating CO₂ within the gel—to keep products cold. The super absorbent polymer absorbs water and turns it into a gel. When frozen, the water and polymer create a matrix that can absorb dry ice gas as the ice sublimates. Because the pack stays flexible, it wraps around products, maximizing contact and slowing heat transfer.
Key operating principles
Stable temperature control: Unlike traditional gel packs that become very hard and lose cooling efficiency when frozen, portable dry ice packs remain somewhat flexible. This flexibility improves their ability to stay in contact with irregularly shaped items
Long lasting cooling: Dry ice sublimates directly from solid to gas at around −78.5 °C. Because the gas escapes through tiny pores, the pack maintains ultra low temperatures for extended periods.
No liquid residue: The sublimation process leaves no meltwater, reducing the risk of soggy packaging.
Environmentally safe materials: The main components—SAP and water—are non toxic. Even if the pack leaks, it poses minimal environmental harm
Applications of portable dry ice packs
Food transportation
Fresh produce, meat and seafood require controlled temperatures during transit. Portable dry ice packs provide a stable low temperature environment that extends shelf life Because they are flexible, they fill space inside coolers more efficiently than rigid blocks, reducing air pockets.
Pharmaceutical logistics
Vaccine and biologic shipments demand precise temperature control. Dry ice packs maintain ultra cold temperatures and meet regulatory standards for transporting vaccines, blood products and biological specimens Since portable packs contain non hazardous materials, they simplify compliance compared with handling pure dry ice, which is classified as hazardous material.
E commerce and meal delivery
Meal kit and grocery delivery services require reliable cooling for both short and long distances. Portable dry ice packs fit into coolers and insulated bags, offering flexibility for small or large orders Because they do not leak, customers receive dry, intact packages, enhancing satisfaction.
Specialty logistics and fieldwork
Field researchers, emergency responders and outdoor enthusiasts often need portable refrigeration. Dry ice packs keep specimens, medicines or food cold without the weight of ice blocks or the complexity of active refrigeration. Their lightweight design saves space and weight.
Advantages and disadvantages of portable dry ice packs
Advantages
Superior temperature stability: Dry ice provides extremely low temperatures and long duration freezing power. Combined with the flexible gel matrix, it keeps cargo cold longer than standard water packs.
Lightweight and space saving: Unused dry ice packs are compact and occupy less space than traditional gel packs This reduces shipping costs.
Safe and environmentally friendly: Materials used in portable dry ice packs are non toxic and easy to dispose of
No meltwater: The sublimation of CO₂ leaves no water residue, preventing moisture damage.
Reusability: Many portable packs can be refrozen and reused multiple times, reducing waste and cost.
Disadvantages and considerations
Handling precautions: Dry ice is classified as hazardous because it emits CO₂ gas that displaces oxygen. While packs reduce direct exposure, proper ventilation is still necessary.
Potential overcooling: Dry ice’s ultra cold temperature can freeze products not intended to be frozen. Careful placement and insulation are required.
Higher cost than water packs: Dry ice packs involve more materials and processing, making them more expensive than simple water packs.
Portable dry ice pack vs. gel packs and water packs
When choosing a cold pack, consider cost, cooling power, eco impact and logistics. The table below compares common options:
| Pack type | Best use | Cost | Eco impact | Ease of use | Cooling power | Logistics complexity |
| Dry ice (portable dry ice pack) | Frozen shipments (seafood, meat, biologics) | High | High environmental impact (requires CO₂ production) | Moderate handling (hazardous classification) | Excellent long duration, ultra low temps | Complex—regulated handling and shipping requirements |
| Gel packs | 24–48 hour chilled shipments (2–8 °C) | Medium | Moderate | Easy to handle | Good—slightly better thermal retention than water packs | Simple logistics |
| Water packs (ice packs) | Short–mid duration chilled shipments | Low | Low (just water) | Very easy | Moderate—lower thermal mass than gels | Very simple |
| Reusable cold packs | Subscription services, pharma delivery | Low long term cost | Low | Moderate; requires return logistics | Variable; depends on material | Infrastructure heavy—needs return/cleaning processes |
Key takeaway: portable dry ice packs offer superior cooling but at higher cost and complexity. Water or gel packs may suit short chilled shipments and are easier to dispose of.
Sector specific recommendations
Food & meal kit delivery: Water or gel packs provide low cost and safe cooling for 2–8 °C products.
Pharmaceutical chill range: Water or gel packs have sufficient thermal stability without overcooling.
Frozen food and ice cream: Dry ice packs are preferred because they maintain ultra low temperatures.
Dairy and cheese: Use water or gel packs to avoid freezing.
Subscription services: Reusable cold packs are cost effective if return logistics are in place.
How to prepare and use portable dry ice packs safely
Preparation steps
Soak thoroughly: Immerse the pack in water for at least 15 minutes to ensure complete absorption
Freeze completely: Place the soaked pack in a freezer at −20 °C or lower until fully frozen Complete freezing prevents hot spots and ensures uniform cooling.
Handle with gloves: Wear insulated gloves to avoid frostbite when transferring frozen packs into containers.
Strategic placement: Arrange packs around the product rather than on top to avoid direct contact with sensitive items Use dividers or cardboard to prevent overcooling.
Ventilation: When using several packs, ensure ventilation. CO₂ gas can build up; open containers slowly to release gas.
Usage tips for different scenarios
Short deliveries (under 24 hours): Use one or two packs in a well insulated cooler. Place one above and one below to maintain consistent temperature.
Long shipments (48–72 hours): Combine dry ice packs with gel or water packs. The dry ice packs keep contents frozen longer, while gel packs help maintain cold after the dry ice sublimates.
Pharmaceutical shipments: Use temperature data loggers to verify compliance. Place dry ice packs outside the primary product container to prevent accidental freezing.
Safety considerations
Avoid airtight seals: Do not seal dry ice packs in airtight compartments; gas release can cause pressure build up.
Transport regulations: Check local and international regulations. In many jurisdictions, shipments containing more than a specified weight of dry ice require hazard labeling.
Disposal: Allow spent packs to warm at room temperature in a ventilated area until all CO₂ has sublimated. The remaining gel can be disposed of in general waste if permitted.
Latest trends and innovations in portable dry ice packs (2025)
The portable dry ice pack market is evolving rapidly. Several key trends shape the industry in 2025:
Market dynamics and supply challenges
Dry ice consumption is growing at roughly 5 % per year while CO₂ supply grows only 0.5 %. This mismatch has led to spot price surges up to 300 % during supply crunches. Nevertheless, demand continues to rise, driven by food shipping, biologics and industrial applications. Analysts estimate the global dry ice market reached USD 1.54 billion in 2024 and will grow to USD 2.73 billion by 2032, a compound annual growth rate of 7.4 %.
Localized CO₂ capture and sustainability
Sustainability pressures are reshaping dry ice production. Companies are capturing CO₂ from bioethanol and other fermentation processes. In the UK, for example, bioethanol plants capture CO₂ released during fermentation and process it into food grade dry ice. One plant accounted for 30–60 % of UK CO₂ supply. However, trade policies and competition from imported bioethanol threaten these operations. This situation highlights the need for diversified, low carbon CO₂ sources.
Hybrid cooling solutions
To mitigate supply risks and over reliance on dry ice, shippers mix dry ice packs with phase change materials (PCMs), gel packs and improved insulation. Hybrid systems stretch the effectiveness of dry ice and reduce the required quantity. Active containers with mechanical refrigeration power also support extended shipments for pharmaceuticals, although they are expensive.
Smart temperature monitoring
Portable dry ice packs are increasingly paired with IoT enabled sensors. These sensors record temperature, humidity and location, allowing real time monitoring and alerts. By analyzing data, shippers can optimize the number of packs used, predict sublimation time and ensure regulatory compliance. This trend aligns with the article’s suggestion that future temperature control will integrate IoT technologies for precise monitoring
Customization and user friendly designs
Manufacturers now offer customized pack sizes, shapes and branding. Some packs incorporate tear away segments so customers can use only the necessary portion. Others have built in color indicators that change when the temperature rises above a set threshold. These innovations improve user experience and reduce waste.
Environmental regulations and recycling
Authorities are tightening regulations on CO₂ emissions and hazardous materials. Companies are exploring recyclable pack materials and bio based polymers. For instance, some suppliers experiment with biodegradable films and compostable gels. This aligns with consumer demand for sustainable packaging.
Frequently asked questions
Q1: How long does a portable dry ice pack last?
The cooling duration depends on the pack size, insulation quality and ambient temperature. In a typical insulated shipper, a 1 kg dry ice pack may last 24–36 hours. Using multiple packs or combining with gel packs can extend duration up to 72 hours.
Q2: Is a portable dry ice pack the same as pure dry ice?
No. A portable dry ice pack contains dry ice within a gel matrix. It offers similar cooling performance but is safer to handle because the dry ice is contained within a sealed pouch. It also releases CO₂ gas gradually through tiny pores.
Q3: Can I refreeze a portable dry ice pack?
Most portable dry ice packs are reusable. After sublimation, allow the pack to return to room temperature, re soak it in water and freeze again. Check manufacturer instructions; repeated use may reduce performance over time.
Q4: What products are unsuitable for dry ice packs?
Products that should not be frozen, such as leafy greens, certain pharmaceuticals or temperature sensitive chemicals, may be damaged by direct contact with ultra cold packs. For these items, use gel or water packs instead.
Q5: Do portable dry ice packs emit harmful gases?
Dry ice sublimates into CO₂ gas, which is non toxic but can displace oxygen in confined spaces. Ensure adequate ventilation when handling large quantities of packs.
Summary of key points
Portable dry ice packs have become an indispensable tool for cold chain logistics in 2025. They offer ultra cold, long lasting cooling, remain flexible after freezing and are made from non toxic materials. Their layered structure—including an outer film, SAP gel and leak proof barrier—allows them to absorb water, freeze into a gel and hold dry ice safely Compared with gel and water packs, dry ice packs provide superior cooling but require careful handling and cost more. They are widely used in food, pharmaceutical and e commerce logistics and are trending in popularity due to market growth and sustainability concerns. Challenges include CO₂ supply shortages and regulatory pressures, but innovations such as localized CO₂ capture, hybrid cooling solutions and smart monitoring are expanding their utility.
Actionable recommendations
Assess your shipping needs: Determine whether products require frozen temperatures or chilled conditions. For frozen goods or biologics, select portable dry ice packs; for chilled items, water or gel packs may suffice.
Optimize pack placement: Soak and freeze packs thoroughly, then position them around items rather than directly on top. Combine with gel packs or insulation for longer shipments.
Invest in monitoring: Integrate IoT temperature sensors to track conditions and adjust the number of packs accordingly. Data insights help reduce waste and ensure compliance.
Plan for supply variability: Diversify cooling strategies. Use hybrid solutions and develop relationships with multiple suppliers to mitigate CO₂ shortages.
Stay updated on regulations: Monitor hazard labeling, weight limits and recycling guidelines in your region. Seek out suppliers who use bio based CO₂ or recyclable materials.
About Tempk
At Tempk, we specialise in cold chain solutions that balance performance, sustainability and cost. Our portable dry ice pack products use high quality SAP gels and leak proof films to deliver consistent ultra low temperatures while remaining lightweight and reusable. We continually invest in material innovation and IoT integration to offer smart, environmentally friendly refrigerants. Our experts can help you design customized cooling strategies for food, pharmaceutical or e commerce applications.
Call to Action: If you need reliable cold chain packaging or want to explore hybrid cooling solutions, contact our team for a consultation. We’ll help you choose the right portable dry ice pack and implement best practices for safe, efficient shipping.
