XL-Size Dry Ice Packs are available across gel and rigid “brick” formats, and case counts are predictable by size. In short: 32 oz usually ship 18 per case, 48 oz ship 12 per case, and 64 oz vary 4–10 per case depending on brand and film/foam style. You’ll also see 60 oz foam bricks at about 6 per case. This guide shows you how to choose, ship, and right-size purchases for 2025.
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What counts as XL-size dry ice packs? Definitions, sizes, and when to choose gel vs. rigid bricks (long-tail: XL gel packs for frozen shipping).
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How many per case, exactly? Case-count norms and why they differ by format (long-tail: 48 oz gel pack 12 per case).
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How many do you need per box? A fast planning rule and validation tips (long-tail: XL dry ice packs case calculator).
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Dry ice vs. −21 °C PCM? Choosing the safest, simplest option for your lane (long-tail: dry ice alternative PCM −21°C).
What counts as XL-size dry ice packs, and which size should you choose?
Answer in brief: XL-size dry ice packs typically mean 32–64 oz refrigerant packs in flexible gel or rigid brick styles. 32 oz fits narrow shippers; 48 oz is the common “large” workhorse; 64 oz delivers fewer touches and longer holds but has wider case-count swings. Dry ice packs here refer to gel/PCM coolants, not solid CO₂.
Why this matters to you: Larger packs cut picks and fill voids with fewer touchpoints. If you need 0–8 °C or moderate frozen holds, gel XL often avoids hazmat headaches. If you must keep ≤−20 °C for long durations, consider real dry ice with PI 954 labeling, or −21 °C PCM bricks when you want non-hazmat deep-frozen control. Always validate against your hottest lane profile.
How many XL-size dry ice packs per case by size?
Most teams standardize procurement using a simple map:
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32 oz (gel): 18/case
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48 oz (gel): 12/case
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64 oz (gel): 4, 8, or 10/case (brand/film dependent)
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60 oz foam brick (rigid): ~6/case
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44 oz rigid brick: 18/case
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56 oz rigid brick: 12/case
| Size & Style (XL) | Typical Case Count | Common Dimensions (in.) | What it means for you |
|---|---|---|---|
| 32 oz gel | 18 / case | ~10.5 × 5.5 × 1.25 | Narrow footprint; easy to stack; good for 24–48 h lanes. |
| 48 oz gel | 12 / case | ~10.5 × 7.5 × 1.25–1.5 | The “standard large”; balanced mass and placement flexibility. |
| 64 oz gel | 4–10 / case | ~11 × 8 × 1.5–2 | Fewer touches; verify brand-specific counts before ordering. |
| 60 oz foam brick | ~6 / case | ~9 × 8 × 1.5 | Rigid shape; resists compression under tight collars. |
| 44 oz rigid brick | 18 / case | ~8 × 8 × 1.75 | Stackable geometry; good for return/reuse programs. |
| 56 oz rigid brick | 12 / case | ~10.5 × 8 × 1.75 | High mass for 48–72 h frozen with robust insulation. |
Practical tips you can apply today
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Frozen D2C, 24–36 h: Use one 64 oz or two 48 oz for similar mass; pick 48 oz if placement flexibility is vital.
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Hot summer lanes (>35 °C), 48 h: Start with two 64 oz or three 48 oz and validate with data loggers.
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2–8 °C biologics, 48 h: One 48 oz + one 24–32 oz often smooths swings better than a single large pack.
Real case: A frozen-food sender replaced four 16 oz packs with two 32 oz XL packs and cut packout time by ~25% while passing a 48-hour summer profile. The bigger units reduced leaks and improved temperature stability.
How many XL-size dry ice packs do you need per shipment?
Direct answer: Match pack mass to payload mass, insulation R-value, lane duration, and ambient swings. As a fast field rule, add one 48 oz for every 12–18 hours of extra exposure beyond a working baseline, then confirm with a chamber test or a lane pilot.
From your perspective: If you’re replacing many small packs, XL-size dry ice packs lower labor and reduce voids. For longer lanes or higher ambient heat, step up to 64 oz or add one more 48 oz. Always precondition packs fully and instrument a few shipments to measure worst-case dwell and sortation delays.
Quick sizing checklist for XL-size dry ice packs
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Target temp: CRT (15–25 °C), Chill (2–8 °C), or Frozen (≤−10 °C)?
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Transit hours: Door-to-door plus 20% slack for delays.
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Insulation: EPS/VIP/paper liner; thicker walls reduce pack mass.
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Payload: High-water foods have “free cooling”; low-moisture payloads warm faster.
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Season & lane: Use a summer profile unless you have proven lane data.
XL-size dry ice packs vs. real dry ice and −21 °C PCM: which fits your lane?
Core guidance:
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Use real dry ice (UN1845) for ultra-low targets or long, hot lanes. Mark “Dry Ice/Carbon dioxide, solid,” add net dry-ice mass (kg), use a Class 9 label, and keep packaging vented (IATA PI 954, 2025).
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Choose −21 °C PCM bricks when you need non-hazmat frozen control (≤−18 °C) for 24–72 h with simpler ops.
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Pick XL-size dry ice packs (0 °C gel) for 2–8 °C and short frozen holds without hazmat handling.
| Coolant | Regulatory status | Typical large-case counts | Your takeaway |
|---|---|---|---|
| Real dry ice (−78.5 °C) | Dangerous goods; IATA PI 954; vented pack required | Sold by weight | Maximum frozen margin; add labeling and training. |
| −21 °C PCM bricks | Not DG | 12–24 / case (large) | Deep-frozen control without hazmat paperwork. |
| 0 °C gel (XL-size dry ice packs) | Not DG | 12–18 / case (32–48 oz) | Easiest for 2–8 °C and moderate frozen holds. |
A copy‑and‑use calculator (paste into your SOP)
2025 trends shaping XL-size dry ice packs
What’s new this year: Air carriers refreshed dry-ice acceptance checklists; gel and −21 °C PCM options keep expanding for simpler ops. More senders validate to seasonal profiles to trim over-icing and reduce chargeable weight. Paper-based liners and returnable systems change coolant mass needs and case-buy planning. Updated passenger baggage rules still cap dry ice at 2.5 kg per traveler; commercial cargo follows PI 954.
Latest developments at a glance
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Compliance clarity: 2025 job aids/checklists make UN1845 marks, net kg, and venting unambiguous.
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Paper liners (48–72 h): Viable recyclable liners reduce gel mass requirements in some lanes.
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Reusable systems: Growth in returnable shippers shifts spend from consumables to conditioning capacity.
Market insight: Pharma/diagnostics and e-grocery volumes continue to raise demand for XL-size dry ice packs and −21 °C PCM bricks. Expect pressure to reduce EPS, right-size gel mass, and document performance with data loggers.
Frequently Asked Questions
Do you offer larger or XL-size dry ice packs? How many per case?
Yes. XL typically means 32–64 oz. Expect 18/case at 32 oz, 12/case at 48 oz, and 4–10/case at 64 oz depending on format.
Are “dry ice packs” the same as real dry ice?
No. Many “dry ice packs” are gel or PCM coolants (non-hazmat). Real dry ice is solid CO₂ and regulated for air shipments.
What labels do I need in 2025 if I use real dry ice?
Mark UN1845, add the net dry-ice mass (kg), apply the Class 9 label, and ensure vented packaging per PI 954.
How many XL-size dry ice packs should I put in one box?
Start points: 1 × 64 oz for 24–36 h frozen; 2 × 48 oz for longer or hotter lanes. Validate with a lane pilot.
Can I fly with dry ice in baggage?
Passengers are limited to 2.5 kg (5.5 lb) per person with airline approval and vented packaging. Cargo uses PI 954.
Summary & recommendations
Key points: XL-size dry ice packs come in standard case counts—18/case (32 oz), 12/case (48 oz), and 4–10/case (64 oz)—with rigid bricks at 12 or 18/case by size. Choose gel XL for 2–8 °C and moderate frozen holds, −21 °C PCM for non-hazmat deep-frozen lanes, and real dry ice when you need maximum frozen margin. Validate with data loggers to match mass to your hottest lane.
Next steps (CTA):
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Pick your XL format: 32 oz (18/case) for 24–48 h, or 48–64 oz for 36–72 h.
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Run a one-box pilot: Instrument with a logger and use a summer profile.
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Lock case forecasts: Use the calculator above and align buys with packout recipes.
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Need help? Request a lane-specific packout and case plan from Tempk.
About Tempk
We design, validate, and supply cold-chain packaging that works in real lanes. Our team helps you choose between XL-size dry ice packs, −21 °C PCM, and real dry ice, then right-size case counts to hit hold times with minimal waste. Advantages you can measure: applied 7E/7D testing and supplier-agnostic optimization so you buy just enough refrigerant—no more, no less.
Call to action: Ready to size and forecast XL-size dry ice packs with confidence? Contact Tempk for a fast quote and a validated packout plan.
