Dry ice container dry ice pack solutions are the backbone of modern cold chain logistics. Whether you ship vaccines, gourmet desserts or biological samples, understanding how to use these ultra cold materials safely and efficiently can make or break your deliveries. This comprehensive guide answers the most pressing questions about dry ice containers and dry ice packs, incorporating the latest 2025 trends, regulations and industry innovations. In the next sections you’ll learn how dry ice works, how much to use, how to package it correctly, and why the market is evolving so rapidly.
Determine the right amount of dry ice for different products and shipment durations, keeping payloads safe without wasting refrigerant.
Select the best container or pack format (blocks, pellets or wraps) based on your cargo and transit time.
Understand regulations and safety rules under DOT and IATA, including labeling, weight limits and packaging requirements.
Compare dry ice to gel packs and phase change materials (PCMs) for temperature range, reusability and sustainability.
Explore 2025 trends and market dynamics shaping the dry ice industry—from CO₂ supply challenges to sustainable production and hybrid cooling systems.
What is Dry Ice and How Do Dry Ice Containers & Packs Work?
Dry Ice Basics: From CO₂ to Ultra Cold Delivery
Dry ice is the solid form of carbon dioxide (CO₂). Unlike water ice, it doesn’t melt; it sublimates directly into a gas. At atmospheric pressure it maintains an astonishing temperature of –78.5 °C (–109 °F). This ultra cold temperature allows dry ice to keep vaccines, biological samples and frozen foods well below freezing for days. Because it converts from solid to gas rather than liquid, shipments stay completely dry—a key advantage when shipping perishable items that shouldn’t get wet or soggy.
Dry ice containers and dry ice packs are purpose built to harness this property. A dry ice container is a sturdy, insulated box—often made of high density polyethylene (HDPE) or expanded polystyrene (EPS)—that holds bulk dry ice blocks or pellets. It has ventilation ports to let the CO₂ gas escape and thick walls to slow sublimation. Dry ice packs, on the other hand, are smaller pouches or wraps containing dry ice pellets or slices. They are designed to fit around products, providing targeted cooling without the bulk of a large container.
Sublimation Explained
When dry ice absorbs heat from the surrounding environment, it doesn’t melt; it sublimates. Sublimation occurs when a solid turns directly into a gas without passing through a liquid phase. Because there is no water involved, the only by product is CO₂ gas. This gas must be vented from the container to prevent pressure buildup, which is why dry ice shippers use vented lids or breathable pouches. Proper ventilation is not just a best practice—it’s a safety requirement.
Why Containers and Packs Matter
The format of dry ice makes a big difference in performance. Large blocks sublimate more slowly, making them ideal for long shipments or bulk goods. Pellets and nuggets offer a larger surface area and therefore cool quickly but disappear faster. Thin slices and custom cuts provide a balance of coverage and duration, fitting neatly into packaging systems to reduce empty space and improve efficiency. Selecting the right format helps you manage sublimation rate, cooling power and overall cost.
Choosing the Right Amount: How Much Dry Ice Should You Use?
Rough Guidelines for Different Payloads
The amount of dry ice you need depends on the product, the transit time and the level of insulation. Overusing dry ice wastes money, while underusing it risks thawing. Several sources offer rule of thumb recommendations:
Pharmaceuticals & vaccines: Use about 5–10 lb (2.3–4.5 kg) per 24 hours for ultra cold vaccines and biologics.
Seafood & meats: Use 1–2 lb (0.45–0.9 kg) per day for smaller shipments of seafood or premium meats. Bulk shippers might double this amount for large containers.
Frozen meals & desserts: A moderate 2–3 lb (0.9–1.4 kg) per day is typically enough to keep frozen meals or ice cream solid for up to 72 hours.
General guideline: For overnight shipments, use a half the payload weight in dry ice; for two day shipments, use the same weight; and for three day shipments, use 1.5 times the payload weight.
These recommendations can vary with container insulation quality and ambient conditions. Always plan for extra dry ice when shipping during hot summer months or over long distances.
Formula for Estimating Dry Ice Needs
One simplified formula used by many carriers is:
Dry Ice (lb) ≈ (Transit Time in hours ÷ 24) × (Average consumption rate per day)
If your transit time is 36 hours and you need 5 lb per day for vaccines, the calculation is (36/24) × 5 = 7.5 lb. Rounding up to 8 lb ensures a safety margin. You should also account for the sublimation rate, typically 3–8 % per day depending on how well your container is insulated.
Best Practices for Packing Dry Ice Containers and Packs
Step by Step Packing Procedure
Pre condition the container. Chill your box or cooler before adding dry ice to reduce thermal shock and slow sublimation.
Place dry ice at the bottom or top depending on your goal. Placing it on top lets cold air sink through the shipment, ensuring even cooling. Placing it below can help maintain a cold base while reducing the risk of direct contact.
Wrap or separate products. Use cardboard or foam separators to prevent direct contact with dry ice; prolonged contact can damage products or freeze sensitive items.
Fill empty space. Minimize voids with bubble wrap, insulating foam or additional dry ice slices to keep cold air circulating efficiently.
Seal correctly but allow gas to escape. Use tape to close the container, but never make it airtight; venting channels or holes are critical to release CO₂ gas and prevent pressure buildup.
Label clearly. Mark packages with “Dry Ice” or “Carbon Dioxide, Solid” and include the net weight and “UN 1845” hazard class. Regulatory agencies require this labeling.
Wear protective gear. Always handle dry ice with insulated gloves and eye protection to avoid frostbite or cold burns. Work in a well ventilated area to avoid CO₂ buildup.
Common Mistakes to Avoid
Using sealed plastic bags for dry ice. These can burst as the gas expands.
Failing to vent the container. A tightly sealed container can explode from CO₂ pressure.
Ignoring weight limits. Airlines restrict passengers to 2.5 kg (about 5.5 lb) of dry ice per person without special paperwork. Commercial shipments may carry more, but each package cannot exceed 200 kg net weight of dry ice.
Using generic boxes for long shipments. Non insulated boxes will result in rapid sublimation and product loss. Invest in purpose built dry ice containers for extended duration.
Table: Recommended Dry Ice Weight vs. Payload Weight & Duration
| Payload Weight (lb) | Recommended Dry Ice for 24 hr | Recommended Dry Ice for 48 hr | Recommended Dry Ice for 72 hr | Practical Implication |
| 10 | 5 lb | 10 lb | 15 lb | Enough for vaccines/samples (two day shipment) |
| 20 | 10 lb | 20 lb | 30 lb | Adequate for frozen foods or ice cream for up to three days |
| 50 | 25 lb | 50 lb | 75 lb | Typical for large meat or seafood shipments |
| 100 | 50 lb | 100 lb | 150 lb | Used for palletized cargo and industrial shipments |
These numbers are starting points and should be adjusted for extreme weather, container insulation or particularly sensitive payloads.
Understanding Dry Ice Regulations and Compliance
DOT and IATA Hazard Classification
Dry ice is considered a Class 9 hazardous material, requiring specific packaging, labeling and documentation. The proper shipping name is “dry ice” or “carbon dioxide, solid,” and the identification number is UN 1845. Packages must bear the Class 9 hazard diamond and indicate the net weight of dry ice.
Weight Limits and Documentation
For passenger airlines, the International Air Transport Association (IATA) allows travelers to carry up to 2.5 kg (5.5 lb) of dry ice per person without additional paperwork. If you exceed this amount, you must file a dangerous goods declaration and follow more stringent packaging requirements. Commercial shipments can carry up to 200 kg of dry ice per package.
Packaging and Ventilation Requirements
Containers must be durable—using fiberboard, plastic or metal—and strong enough to withstand handling. However, they must also allow CO₂ gas to escape. Jerricans and steel drums are not suitable because they can explode when pressure builds. Airlines and carriers typically require polystyrene foam boxes or specially designed containers with venting ports, like those from AirSea USA that maintain temperatures below –20 °C and release gas safely.
Triple Packaging Rule for Biological Samples
When shipping infectious substances or certain biological products, you must use triple packaging: a primary watertight receptacle, a secondary watertight packaging with absorbent material, and a strong outer box. Each layer must be leak proof. The outer container should be labeled with the dry ice weight and hazard classification.
Dry Ice vs. Gel Packs vs. Phase Change Materials (PCMs)
Temperature Range and Performance
Dry ice delivers extreme cold at –78.5 °C and keeps products frozen for 48–72 hours. Gel packs, by contrast, maintain temperatures in the 0 – 10 °C range and are ideal for chilled rather than frozen goods. PCMs are engineered to hold narrow temperature bands—common ranges include 2–8 °C for refrigerated items or –20 °C for frozen goods.
Reusability and Sustainability
Gel packs and PCMs can be reused multiple times as long as the packaging remains intact. Dry ice, however, sublimates and is single use; once it’s gone, you need more. PCMs have higher upfront costs but offer long term savings and reduce hazardous materials handling. In contrast, dry ice is cheaper per shipment and widely available, though its production relies on CO₂ sources, which carry environmental impacts.
Regulatory Considerations
Gel packs and most PCMs are classified as non hazardous, which simplifies shipping and reduces paperwork. Dry ice requires hazardous materials training, labeling and sometimes dangerous goods declarations. Carriers such as FedEx or UPS set additional rules that shippers must follow, including weight limits and packaging standards.
Table: Comparing Dry Ice, Gel Packs and PCMs
| Cooling Method | Temperature Range | Duration | Hazard Class | Reusability | Best Use Cases |
| Dry Ice | –78.5 °C (solid CO₂) | 48–72 h | Class 9 hazardous | Single use | Ultra cold shipments: vaccines, biologics, frozen meat |
| Gel Packs | 0–10 °C (water based) | 12–24 h | Non hazardous | Reusable | Chilled foods, produce, some vaccines |
| PCMs | –20 °C or +2–8 °C (custom) | 24–96 h | Non hazardous | Reusable | Vaccines, biologics requiring narrow temperature bands |
Which Should You Choose?
If your products must remain frozen (e.g., ice cream, certain vaccines or cell therapy products), dry ice is the gold standard. Gel packs are excellent for refrigerated but not frozen goods like prepared meals or produce, and they offer lower shipping costs and simpler handling. PCMs occupy a middle ground: they provide precise temperature control and can reduce dry ice consumption when combined in a hybrid system. Many shippers are now mixing PCMs with smaller amounts of dry ice to extend hold times while reducing hazardous materials.
Innovations and 2025 Trends in the Dry Ice Industry
Market Dynamics: Demand vs. Supply
Demand for dry ice has been rising about 5 % per year, yet CO₂ supply growth is just 0.5 % annually, creating a persistent shortage and price volatility. Spot prices can spike as high as 300 % during supply crunches. Despite these headwinds, the global dry ice market was valued at USD 1.54 billion in 2024 and is projected to reach USD 2.73 billion by 2032, a compound annual growth rate of 7.4 %. Growth is driven by food shipping, biologics and vaccines, and industrial applications like blasting and welding.
Industry Responses to Shortages
To counter supply issues, manufacturers are building localized production hubs and exploring on site CO₂ capture at facilities like food processing plants. Shippers are diversifying their strategies by combining dry ice with phase change materials and improving insulation to stretch each pound further. Long term supply contracts are also replacing spot buying, giving priority access to critical sectors.
Sustainability and Bio Based CO₂
There is growing pressure to reduce the carbon footprint of dry ice production. Most industrial CO₂ is fossil based, but bio ethanol plants offer a more circular source. During fermentation, bio ethanol producers capture high purity CO₂ that can be purified and turned into dry ice. In the UK, for example, the Ensus bio ethanol plant produces as much as 30–60 % of the country’s CO₂ supply. However, geopolitical issues and trade policies threaten these operations, showing the fragility of supply.
Alternatives and Hybrid Systems
While dry ice is indispensable for ultra cold shipments, alternatives are gaining traction. Gel packs and PCMs provide narrow temperature ranges for less critical goods, mechanical refrigeration systems supply active cooling, and improved insulation reduces the amount of dry ice needed. These alternatives are not replacing dry ice but are being layered in strategically to reduce reliance and support sustainability goals.
Sector Specific Trends
Food & Beverage: Shippers are using thinner slices and pellets for rapid cooling on processing lines, while investing in high performance insulated boxes to cut sublimation losses.
Pharmaceutical & Biotech: Barrier technologies and real time monitoring are being tested to prevent supercooling and to track payload conditions. Hybrid shipments using PCMs for less temperature critical medicines are becoming popular.
Industrial & Welding: Contractors are investing in local pelletizing capacity to secure supplies and avoid being deprioritized during shortages.
Real World Applications and Case Studies
Example 1: Shipping Gene Therapy Vectors
Gene therapy products often require temperatures below –60 °C to maintain viral vector stability. A biotech company used a dry ice container with blocks and pellets layered together. By pre conditioning the container and filling empty spaces with custom dry ice slices, they maintained the required temperature for 72 hours during international transit. Temperature monitors showed a range of –65 °C to –70 °C, ensuring product integrity without supercooling.
Example 2: Gourmet Ice Cream Fulfillment
An artisanal ice cream business needed to ship 50 tubs to customers across the country. They selected a container with an insulated shell and used 30 lb of dry ice for each 20 lb shipment, following the rule of 1.5 times the payload weight. They added foam spacers to minimize voids and inserted small gel packs around the edges to preserve shape. The result: customers reported ice cream arriving solid after two days in transit, even in midsummer conditions.
Example 3: Clinical Trial Samples
A clinical research organization shipped blood samples requiring a 2–8 °C range. Instead of dry ice, they used a PCM shipper combined with a small dry ice pack to cool the payload quickly. After 24 hours, the PCM maintained temperatures between 3–4 °C while the dry ice had fully sublimated. The hybrid approach simplified compliance and minimized hazardous handling, providing an efficient solution for the trial.
Frequently Asked Questions
Q1: How long does dry ice last?
Dry ice typically lasts 48–72 hours in a well insulated container, though the exact duration depends on the amount used and ambient temperature. A thicker container and pre conditioning can extend this period.
Q2: How do I dispose of dry ice after use?
Allow remaining dry ice to sublimate in a well ventilated area away from people or pets. Never place it in a sealed container or a trash bin. Once it has completely sublimated, you can recycle the packaging or reuse the container.
Q3: Is dry ice safe to handle?
Dry ice is safe when handled properly. Wear insulated gloves, goggles and long sleeves to prevent frostbite. Never ingest or handle dry ice with bare hands. Ensure good ventilation to avoid carbon dioxide buildup.
Q4: Can I ship dry ice internationally?
Yes, but you must comply with IATA and local hazardous materials regulations, including weight limits, labeling and documentation. Check carrier guidelines and destination country rules before shipping.
Q5: What is the difference between dry ice packs and gel packs?
Dry ice packs provide ultra cold temperatures and keep products frozen; gel packs maintain refrigerator temperatures and are safer to handle, suitable for chilled but not frozen goods.
Practical Tips and Advice
During peak summer months, increase the amount of dry ice by 20–30 % and consider using reflective packaging to reduce heat transfer.
Use temperature monitors or data loggers inside the container. Real time tracking allows you to respond quickly if temperatures drift.
Stay compliant by training shipping staff. Hazardous materials training reduces errors and penalties.
Plan ahead for supply shortages. Secure supply contracts or consider hybrid cooling systems to reduce dependence on spot dry ice purchases.
Pro tip: For e commerce companies shipping frozen foods during holiday season, a mix of dry ice pellets for initial chill and PCM bricks for sustained cooling can cut dry ice consumption by up to 30 % while still maintaining product quality.
2025: Looking Ahead
The dry ice market in 2025 is evolving rapidly. Supply shortages, price volatility and sustainability concerns are driving innovation. Companies are investing in localized production, exploring bio based CO₂ sources, and incorporating hybrid cooling systems. At the same time, regulatory attention is increasing as authorities emphasize safety and environmental impact. Shippers must adapt by improving insulation, mixing cooling technologies and staying compliant with evolving rules. The industry’s resilience will depend on collaboration between producers, shippers and regulators—ensuring that essential medicines reach patients, foods stay fresh and industrial processes operate smoothly.
Internal Link Suggestions
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Read our comparison of Insulated Shipping Containers to find the right container for your operation.
Discover Best Practices for Vaccine Shipping to maintain regulatory compliance.
Learn how to Recycle or Reuse Cold Chain Packaging for sustainable operations.
About Tempk
Tempk specializes in cold chain solutions for the life sciences, food and logistics industries. We design and manufacture high performance insulated containers, dry ice packs and phase change materials. With decades of experience and a commitment to sustainability, we provide reliable cold chain systems that meet the latest regulatory standards. Our products are tested for thermal performance and durability, ensuring your shipments arrive in perfect condition. Learn more about our offerings and consult our experts to build a custom solution that fits your needs.
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Contact Tempk today to discuss your cold chain challenges and find the right mix of dry ice, gel packs and PCMs for your shipments. Our experts will help you design a compliant, cost effective solution that keeps your products safe from origin to destination.
