Shipping Dry Ice Pack Sheet: 2025 Compliant Guide

If you need a shipping dry ice pack sheet that teams follow on the first try, this guide gives you a copy‑ready SOP, PI 954 labeling checklist, and a quick sizing method. You’ll see what to mark (UN 1845, Class 9, net kg), how to vent, and how much dry ice to load for 24/48/72‑hour lanes. You’ll cut acceptance failures and protect product with current 2025 rules.

The shipping dry ice pack sheet essentials for PI 954 and 49 CFR compliance
How much dry ice for 24/48/72‑hour shipping (with a fast estimator)
What to label, mark, and record so carriers accept at first scan
How to validate with ISTA 7D/7E profiles before you scale
When to use dry ice vs. “dry ice pack sheets” (gel)

What is a shipping dry ice pack sheet (SOP) and why does it matter?

Direct answer
A shipping dry ice pack sheet is a one‑page, step‑by‑step SOP that tells packers how to assemble, label, and document each UN 1845 shipment. It shows the net dry ice (kg) to load, label placement (Class 9, 100 mm), and the records to capture so your box passes acceptance the first time.

Expanded explanation
Think of it as a recipe card: PPE → box/liner → payload → dry ice placement → vent → mark “Dry Ice/Carbon dioxide, solid,” UN 1845, net kg → record time and initials. The sheet maps your QA plan to the IATA 2025 dry‑ice acceptance checklist, and for U.S. moves it echoes 49 CFR 173.217 venting and marking basics. That alignment is what keeps surprises off the dock.

The minimum your sheet must include (PI 954 long‑tail)

Details

Proper shipping name: Dry Ice or Carbon dioxide, solid
UN 1845 and net dry ice weight in kilograms on the outer box
Class 9 label (≥ 100 mm) on the same face when space allows
Packaging that permits CO₂ to vent (no airtight closures)
Shipper/consignee names and addresses (not inside the diamond)

Label/Marking	Requirement	Where	Why it matters to you
Proper shipping name	“Dry Ice” or “Carbon dioxide, solid”	Outer box	Mirrors IATA acceptance checks
UN 1845	6–12 mm text height (by package capacity)	Same face when possible	Fast visual confirmation
Net dry ice (kg)	Kilograms only	Near shipping name	Required for acceptance and booking
Class 9 diamond	100 × 100 mm minimum	Same face if space	Meets size rule and avoids relabel

Practical tips & suggestions

Air lanes: Align your sheet to IATA PI 954 and any operator variations.
U.S. ground/water: Keep 49 CFR 173.217 venting language visible; vessel moves need special markings (“WARNING CO₂ SOLID (DRY ICE)”).
Global ops: Localize by region and mirror carrier acceptance job‑aids.

Case in point: A biotech added a bold “Net dry ice (kg)” line and a 4‑point label check to its sheet. Acceptance failures dropped to near zero in two weeks across three hubs, eliminating rework and fees.

How much dry ice should your shipping dry ice pack sheet specify?

Direct answer
Start from your last passing test at the target duration, then add 10–25% for hotter lanes or bigger payloads, and confirm with a quick ambient test and a data logger. Use ISTA 7D (24/48/72 h) or 7E profiles as guardrails before rollout.

Expanded explanation
For most 2‑day lanes with a 6 L payload in EPS, 3–4 kg dry ice is a practical starting point; for 72 h, use higher‑retention shippers (e.g., VIP) and raise load. Run one chamber test against a 48 h summer curve and one winter curve to check “too cold” risk, then lock the kg into your sheet.

Quick lane‑based estimator (how much dry ice for 48‑hour shipping?)

Details

24 h lane, EPS + 6 L payload: 1.5–2.5 kg
48 h lane, EPS + 6 L payload: 3–4 kg
72 h lane, VIP + 6 L payload: 4–6 kg
Validate with a chamber or ambient test and a logger; adjust ±15%.

Test Type	Profile	Pass Criterion	What you capture
Chamber	ISTA 7D 48 h Summer	Payload stays ≤ max temp	Net kg, placement, time‑to‑warm
Chamber	ISTA 7D 48 h Winter	Payload stays ≥ min temp	Too‑cold risk, need for buffers
Live lane	Actual route	Inside label range	Real‑world variability vs chamber

90‑second self‑check (interactive)

Can you point to net dry ice (kg) on the box in 3 s?
Is the Class 9 label ≥ 100 mm, same face as the name when possible?
Does your shipper vent CO₂ per 49 CFR 173.217?
Did you log seal time, initials, and logger ID?

PI 954 labeling checklist for your shipping dry ice pack sheet (what to write and where)?

Direct answer
Mark the box with “Dry Ice/Carbon dioxide, solid”, UN 1845, and net kg, apply a 100 mm Class 9 label, keep addresses outside the diamond, and ensure the packaging vents. Use the IATA 2025 dry‑ice acceptance checklist during handoff.

Expanded explanation
Carrier job‑aids now call out minimum text sizes for UN 1845 and emphasize keeping the net kg legible, not scribbled inside the diamond. If you overpack, mark the overpack total (kg). Some operators also request the net kg during booking to stay within aircraft carbon‑dioxide limits—add a booking line to your SOP.

Don’t mix up baggage allowances with cargo rules

The 2.5 kg figure you may see applies to passenger baggage, not most cargo shipments. Cargo is governed by PI 954 and operator limits, with some carriers requesting net kg at booking.

49 CFR 173.217 venting: what must your shipping dry ice pack sheet say?

Direct answer
Your packaging must vent CO₂ to prevent pressure build‑up. For vessel moves, add “WARNING CO₂ SOLID (DRY ICE)”/“DO NOT STOW BELOW DECKS”; for air, mark net mass (kg) on the outside and coordinate with the operator.

Expanded explanation
Include a bold “VENT” reminder in the closing step, and train drivers not to store boxes in sealed trunks. For team safety, align training to OSHA 5,000 ppm TWA and NIOSH 40,000 ppm IDLH limits.

Safety snapshot (CO₂ exposure long‑tail)

OSHA PEL: 5,000 ppm (8‑h TWA)
NIOSH IDLH: 40,000 ppm
Keep rooms/vehicles ventilated; never block vent paths.

Test & validate your shipping dry ice pack sheet (ISTA 7D/7E quick path)

Direct answer
Qualify packs with ISTA 7D (24/48/72 h) and consider 7E profiles when you need parcel‑environment realism. Run summer first, then winter, then a live pilot with loggers.

Expanded explanation
Locking the net kg on your sheet should always follow a passed test with margin. Use the same payload, shipper, and pre‑condition, and capture time‑to‑warm and too‑cold risks so you’re ready for audits and seasonal swings.

Copy‑ready pack‑sheet snippet (paste as needed)

pack_sheet_title: Shipping Dry Ice Pack Sheet (2025)

lane: "48h Air"

shipper_type: "EPS 30 mm"

payload: "6 L (boxed)"

dry_ice_net_kg: 3.5

steps:

  - "PPE on; confirm ventilation."

  - "Precondition product; load liner."

  - "Add 2.0 kg dry ice base; center payload."

  - "Add 1.5 kg dry ice top; close liner; leave vent path."

  - "Mark: 'Dry Ice'/'Carbon dioxide, solid', UN 1845, net kg."

  - "Affix Class 9 label (≥100 mm)."

  - "Record seal time, initials, logger ID."

notes:

  - "Hot lanes or larger payloads: +10–25% dry ice."

  - "VIP shipper may reduce load after validation."

Adapted from our internal SOP template and improved for 2025 acceptance and booking needs.

“Dry ice pack sheets” (gel) vs. real dry ice: which should you use?

Direct answer
Gel “dry ice pack sheets” are not dry ice. They freeze near –20 °C, are not regulated as dangerous goods, and suit chilled/frozen ranges (e.g., 2–8 °C or ≤0 °C). Use real dry ice (–78.5 °C) for deep‑frozen lanes or where long hold times are needed—then follow PI 954/49 CFR rules. (Industry practice; regulatory sources above.)

Expanded explanation
For vaccines and biologics, health authorities caution not to store vaccines on dry ice because it can over‑cool. Use validated fridges/freezers and data loggers for routine storage or emergency moves. In short: gel for chilled, dry ice for deep‑frozen + regulated, and always validate.

Real‑world rule of thumb

Chilled (2–8 °C): Gel sheets/PCM, validate with 7E
Frozen (≤0 °C to –20 °C): Gel + high‑retention shipper or small dry‑ice top‑up
Deep‑frozen (≤–50 °C): Dry ice with PI 954 compliance

2025 developments & trends (shipping dry ice pack sheet)

Trend overview
In 2025, operators continue to enforce IATA acceptance checklists for dry ice, and some carrier variations require net dry ice at booking to respect aircraft‑type limits. Expect renewed emphasis on 100 mm Class 9 labels, clear kg markings, and electronic acceptance flows tied to declared net kg.

Latest at a glance

Booking transparency: Some operators request net kg during booking to compare against aircraft limits.
Checklist discipline: The 2025 dry‑ice acceptance checklist remains a standard touchpoint.
Label clarity: Carriers reinforce 100 mm Class 9 and kg‑only net weight marks to reduce rework.

Market insight
Healthcare and food e‑commerce continue to drive cold‑chain volume. Shippers favor validated insulation, IoT logging, and rightsized dry‑ice loads to balance cost, risk, and emissions—then capture that in a concise shipping dry ice pack sheet.

FAQ (featured‑snippet ready)

Q1: Do I need a Shipper’s Declaration for dry ice?
Often no when dry ice cools non‑dangerous goods—but the IATA acceptance checklist and full markings still apply. IATA

Q2: Is there a 2.5 kg limit for dry ice in cargo?
That 2.5 kg limit applies to passenger baggage. Cargo follows PI 954 and operator limits; some carriers ask for net kg at booking.

Q3: What size must the Class 9 label be?
100 × 100 mm minimum; don’t write inside the diamond.

Q4: What safety lines should my SOP include?
Vent packaging (49 CFR 173.217) and train staff to OSHA 5,000 ppm TWA and NIOSH 40,000 ppm IDLH.

Q5: Should I use dry ice for routine vaccine storage?
No. Health authorities advise against dry ice for routine storage—use validated units and data loggers.

Summary & recommendations

Key points
Use a shipping dry ice pack sheet that is visual and checklist‑driven. Mark UN 1845, net kg, and Class 9 (100 mm); ensure venting; and validate with ISTA 7D/7E before scale‑up. Add a booking net‑kg line for operators who require it.

Next steps (do this now)

Copy the YAML snippet and create 24/48/72 h variants.
Run one ambient or chamber validation and log results.
Train packers with a 10‑minute label/mark drill.
Add a booking net‑kg field to your SOP.
Review quarterly to trim dry‑ice load without risk.

About Tempk

Who we are
We are a cold‑chain packaging and analytics team focused on simple SOPs and data‑driven packouts. Our strengths: fast lane modeling and clear training materials that reduce acceptance failures and dry‑ice waste.

Call to action
Ready to tailor your shipping dry ice pack sheet to your lanes and products? Consult a Tempk specialist for a fast, compliant review.