UK Dry Ice Packs: How to Ship Frozen Goods Safely?

You want frozen products to arrive rock‑solid without expensive over‑packing. UK dry ice packs keep goods below –18 °C for long lanes when gel or standard PCM can’t cope. In this 2025 guide, you’ll get right‑sizing rules, IATA/ADR labeling, carrier do’s and don’ts, and field‑tested pack‑outs that lower cost and risk on UK routes.

How do UK dry ice packs work and when are they the right choice for frozen shipping in the UK?
How many kilograms of dry ice hold for 24–96 hours on typical UK lanes and seasons?
How to pack and label UK dry ice packs to meet IATA PI 954 and ADR requirements?
Should you choose UK dry ice packs or –21 °C PCM or gel packs for different payloads?
What 2025 trends affect sourcing, safety, and sustainability of UK dry ice packs?

What are UK dry ice packs and when should you use them?

Dry ice is solid carbon dioxide (UN 1845), class 9, at –78.5 °C; it cools as it sublimates to gas. That ultra‑low temperature gives UK dry ice packs unmatched “cold headroom” for ice cream, biologics, and specialty foods over 48–96‑hour lanes or during heat spikes. It’s ideal when you must maintain deep‑frozen stability or recover quickly from depot dwell.

Why it matters: Each kilogram of dry ice absorbs substantial heat as it turns to CO₂ gas, so small masses deliver big protection. Because CO₂ gas is heavier than air, you must vent packages and storage areas to avoid oxygen displacement risks.

How do UK dry ice packs differ from gel or –21 °C PCM?

“Extra cold” in practice means deeper temperature capability and higher cooling capacity. Gel holds around 0 °C and suits chilled. –21 °C PCM stabilizes frozen but struggles with long hot dwell. UK dry ice packs run at –78.5 °C, offering faster pull‑down and better recovery from short heat spikes, if you respect venting and labeling rules.

Cooling Source	Typical Temp Band	What to expect	What it means for you
UK dry ice packs (UN 1845)	–78.5 °C	Deep‑freeze control; gas needs venting	Best for frozen, 48–96 h; label Class 9
–21 °C PCM	~–21 °C plateau	Stable but less “recovery power”	Good for stable 24–72 h lanes
Gel packs	0 °C to –5 °C	Chilled only	Not for deep‑frozen payloads

Practical tips you can use today

Top‑load placement: Put UK dry ice packs above the payload; CO₂ gas sinks and bathes goods in cold air.
Create gas paths: Never seal gas‑tight; a small vent or “breathing” lid prevents pressure build‑up.
Protect people: Use insulated gloves and eye protection; avoid confined, unventilated rooms.

Real‑world example: A UK dessert brand moved to top‑loaded UK dry ice packs with a vented lid and reduced summer failures from 6.5% to under 1% while trimming coolant by ~15% after logger validation.

How to size UK dry ice packs for 24–96 hours?

Start with heat load, then convert to kilograms of dry ice. A field rule for mid‑size EPS (12–24 L) is 2–3 kg for ~24 h, 4–6 kg for ~48 h, and 6–9 kg for ~72 h—always validate with loggers and your lane profile. Better insulation (2″ EPS or VIP) cuts mass substantially. The goal is right‑sizing, not oversizing.

A simple 5‑step sizing method (you can copy)

Estimate heat leak (Q̇): U‑value × surface area × ΔT.
Multiply by time: $\times t$ (kJ).
Add product pull‑down: If starting above target.
Add 20–30% safety margin: For depot dwell or weekend hold.
Divide by 571 kJ/kg: First‑pass kilograms of UK dry ice packs.

Lane Duration	EPS 1.5″ wall	EPS 2.0″ wall	VIP shipper	What it means
24 h	2–3 kg	1.5–2.5 kg	1–2 kg	Start lean; validate with two loggers
48 h	4–6 kg	3–5 kg	2–4 kg	Add buffer in summer
72 h	6–9 kg	5–7 kg	3–6 kg	Consider side runners
96 h	8–12 kg	7–10 kg	5–8 kg	Move to VIP + hybrid PCM

“UK dry ice packs” quick‑calc you can adapt

Pro tip: Logger curves reveal when dry ice is gone—the temperature slope steepens. If that happens long before delivery, increase mass or upgrade insulation, not both.

How to pack and label UK dry ice packs to comply?

Follow IATA Packing Instruction 954 (air) and ADR (road), mark UN 1845 “Carbon dioxide, solid (Dry ice)”, and display net dry ice mass in kg with a Class 9 label. Packages must allow CO₂ to escape to prevent pressure build‑up; never use airtight containers.

Document updates for 2025: The IATA DGR 66th Edition addendum (April 30, 2025) re‑emphasizes aircraft‑type limits for UN 1845 and the requirement to indicate the net dry ice weight. Keep your ops manual aligned with the current addendum and carrier variations.

UK carrier reality check (parcel networks)

Royal Mail/Post Office: Consumer parcels cannot use dry ice for food; the guidance explicitly says “Don’t use dry ice or frozen water.” Businesses should also verify restricted goods lists before attempting DG shipments.
Express integrators (FedEx/UPS): Dry ice is accepted as dangerous goods with PI 954 rules; contracts or DG approvals may be required.
DPD/road networks: Policies vary by country and service; dry ice as a coolant is possible under DG frameworks, but check operator guidance and ADR obligations.
Government overview: If you transport dangerous goods by road, follow official packing and labeling rules and ensure driver/company compliance.

Important nuance: A shipper’s declaration is generally not required for packages containing only UN 1845 used as a refrigerant for non‑dangerous goods, but you must still apply PI 954 markings/labels and net mass. Confirm carrier‑specific variations.

Vented packaging and labeling for UK dry ice packs

Do this every time:

Use packaging designed to vent CO₂ gas.
Mark “UN 1845”, “Dry Ice” or “Carbon dioxide, solid”, and the net kg of dry ice.
Affix the Class 9 hazard label in the correct format and position.

Requirement	Why it matters	How to do it	For you
Venting	Prevents pressure build‑up	“Breathing” lid or vent holes	Safety & compliance
UN 1845 + net kg	Carrier acceptance	Print net mass legibly in kg	Faster induction
Class 9 label	DG identification	Use correct size & orientation	Avoid refusals

UK dry ice packs vs –21 °C PCM vs gel: which wins your lane?

Match cold source to your temperature target and lane volatility. For deep‑frozen products and unpredictable dwell, UK dry ice packs deliver the best protection. For stable 24–48 h frozen lanes, –21 °C PCM can work and simplifies handling. Gel is ideal for chilled (0–5 °C) and not for deep freeze.

Total cost and risk trade‑offs

UK dry ice packs: Highest “cold headroom,” needs PPE, venting, labeling; economical for high‑value frozen goods.
–21 °C PCM: Great for stability and reusability; add a small top‑load of dry ice for summer heat spikes.
Gel: Cheapest pack‑out, but only for chilled.

Option	Materials cost	Handling	Best use	What it means
UK dry ice packs	Medium	DG labeling & PPE	Frozen, 48–96 h	Lowest spoilage risk
–21 °C PCM	Medium‑High	Simple	Frozen, 24–72 h	Stable temps
Gel packs	Low	Simple	Chilled, 12–48 h	Not deep‑freeze

Safety basics for UK dry ice packs (people and places)

Risks: Asphyxiation in poorly ventilated spaces, cold burns/frostbite, pressure build‑up in sealed containers. UK health and safety bodies and UK suppliers emphasize ventilation, PPE, and training as the core controls.

Practical controls:

Work in well‑ventilated rooms; monitor CO₂ where necessary.
Wear insulated gloves and eye protection; use tongs or scoops.
Store UK dry ice packs in insulated, non‑airtight containers; never in sealed car boots.
Train staff; keep SOPs simple and visual.

Note for air passengers (not cargo): UK CAA guidance limits personal baggage to ≤2.5 kg of dry ice per person when used to pack perishables, subject to airline approval. This is separate from cargo rules under PI 954.

Building a compliant pack‑out with UK dry ice packs

Use a top‑load, side‑runner design with a corrugate barrier and vent path. This pattern improves cold wash over the payload and reduces shifting.

Step‑by‑step pack‑out (repeatable SOP)

PPE & staging: Gloves, goggles, tongs, kraft wrap.
Box prep: Insert liner, tape seams, leave a vent gap.
Load product: Pre‑frozen items in a snug inner carton.
Add coolant: Top‑load UK dry ice packs; add side runners if space allows.
Void fill: Kraft paper; avoid blocking vents.
Seal & label: Vented lid; apply UN 1845, net kg, and Class 9; add orientation arrows.
Handoff: Record net kg and box ID in WMS for traceability.

Pack‑out QA signals to watch

Logger signal	What you see	Likely cause	What to change
Early plateau end	Temp rises after 12–18 h	Too little dry ice	Add 20–30% mass
Saw‑tooth swings	±5–10 °C oscillation	Loose pack‑out	Fill voids; add side runners
Gradual warm trend	~0.5–1 °C/h rise	Insulation leak	Upgrade to 2″ EPS or VIP

Sustainability and cost: can UK dry ice packs be greener?

Yes—right‑size the mass, upgrade insulation, and reduce failures. VIP or thicker EPS cuts required kilograms, lowering emissions from production and sublimation. Pair –21 °C PCM on the sides with a small top‑load of UK dry ice packs for recovery, not base load.

Disposal and storage: Ventilate rooms and vehicles; never dispose of dry ice in sinks or sealed bins. UK safety guidance highlights CO₂ displacement hazards and recommends well‑ventilated areas for use and disposal.

Three fast wins

Improve R‑value before adding mass: Insulation upgrades often save 20–40% dry ice.
Lane‑specific standards: Different UK lanes need different net kg; avoid one‑size‑fits‑all.
Post‑delivery guidance: A one‑page insert for recipients reduces incidents and support calls.

2025 trends in UK dry ice packs and frozen logistics

Regulatory clarity and data‑driven right‑sizing are the big shifts in 2025. The IATA DGR 66th Edition addendum (April 2025) underscores aircraft‑type limits and net‑mass indications for UN 1845, while carriers refresh acceptance checklists. UK frozen retail remains resilient, with trade press and market trackers reporting ongoing value growth and category innovation.

Latest developments at a glance

Updated acceptance checklists: Standardized PI 954 checks reduce induction errors and rejections.
Carrier policy transparency: FedEx/UPS UK refresh “how to ship dry ice” pages; contracts may be required.
Category momentum: UK frozen continues to attract shoppers seeking value and convenience, supporting more small‑batch frozen D2C offers.

Market insight: Despite price pressures, frozen convenience stays attractive in UK baskets, keeping demand steady for UK dry ice packs to protect high‑value frozen goods in e‑commerce and B2B lanes.

Image references (illustrative)

Interactive checklist: are your UK dry ice packs ready?

Score 0–2 for each item (0 = no, 1 = partly, 2 = yes). Add your points.

Lane profile validated with loggers in the past 90 days
Insulation verified (≥2″ EPS or VIP for ≥72 h lanes)
UK dry ice packs top‑loaded with side runners and barrier sheet
Vented lid; Class 9 label; UN 1845 + net kg marked
SOP card for receivers; PPE available at pack‑out

Results:

8–10 points: Good to ship frozen confidently.
5–7 points: Adjust mass or insulation and re‑test.
0–4 points: Pilot two pack‑outs before going live.

UK dry ice packs: FAQs

Can I send food with UK dry ice packs via Royal Mail?
No. Royal Mail guidance for sending food says don’t use dry ice or frozen water in parcels. Use DG‑capable couriers instead.

What must appear on the label for UK dry ice packs by air?
Display “UN 1845”, the words “Dry Ice” or “Carbon dioxide, solid”, the net weight in kg, and a Class 9 hazard label; the packaging must vent gas.

Do I need a shipper’s declaration if I only use UK dry ice packs?
Generally no—when dry ice cools non‑dangerous goods, a declaration isn’t required, but PI 954 markings still apply and operator variations may exist.

Are there special contracts for integrators?
Yes. UPS notes that dry‑ice shipments may require an ISC or DG contract; FedEx UK provides dry‑ice instructions and training requirements.

What about road transport requirements in the UK?
ADR applies to dangerous goods by road; ensure proper packaging, marking, and driver/company compliance.

Is dry ice safe to handle?
With ventilation, gloves, and eye protection, yes. Risks include asphyxiation and cold burns; follow UK safety guidance.

Summary & next steps for UK dry ice packs

Key takeaways: UK dry ice packs deliver the deepest freeze margin for UK lanes, but compliance matters. Right‑size by calculating heat load, then validate with loggers. Pack top‑load with vent paths, mark UN 1845 with net kg, and apply Class 9. For stability and sustainability, combine VIP or –21 °C PCM with a smaller dry‑ice top‑load.

Action plan: Pilot two pack‑outs with different UK dry ice packs masses and log both; upgrade insulation before adding kilograms; publish a one‑page SOP; confirm 2025 PI 954/ADR requirements with your carriers; review results in 30 days and lock lane standards.

About Tempk

We are a UK‑focused cold chain team delivering validated pack‑outs, compliant labeling, and lane‑specific sizing for UK dry ice packs. Our solutions include VIP/EPS shippers, –21 °C PCM, SOP templates, and training that reduce failures and total cost. We pair field testing with simple tools so your shipments arrive frozen—and stay that way.

CTA: Request a free frozen‑lane audit and get a tailored UK dry ice packs sizing sheet for your network.