How do flexible ice dry ice pack sheets revolutionize cold chain shipping in 2025?
Keeping vaccines, biologics and perishable foods at the right temperature during transit can make the difference between a life saving delivery and a spoiled shipment. Flexible ice dry ice pack sheets – also called rapid freeze dry ice blankets – are lightweight, moldable packs filled with solid carbon dioxide or phase change materials that reach extreme cold temperatures. These sheets can wrap around irregular shapes and keep goods frozen at –78.5 °C for up to 72 horas. As the cold chain industry faces rising energy costs and stricter sustainability goals, flexible dry ice sheets offer a versatile solution. In this comprehensive guide you will learn how these sheets work, how to size them correctly, best practices for safe handling and the latest 2025 innovations shaping temperature controlled logistics.
Understand what a flexible ice dry ice pack sheet is and why it can maintain temperatures as low as –78.5 °C.
Compare dry ice sheets with traditional gel packs and phase change materials (PCMs).
Apply sizing and layering guidelines for 24–72 hour shipments.
Follow safety and regulatory requirements, including hazardous classification and labeling.
Explore sustainability trends, smart sensors and market dynamics shaping 2025 embalagem da cadeia de frio.
What is a flexible ice dry ice pack sheet and how does it differ from standard ice packs?
Direct answer and core benefits
Flexible dry ice pack sheets are thin, pliable blankets filled with solid carbon dioxide (gelo seco) or advanced phase change materials. Each sheet contains super absorbent polymer cells that are hydrated before freezing to create a network of pockets that encapsulate CO₂. Quando congelado, the sheet becomes a flexible cold layer that can wrap around irregularly shaped cargo. Because dry ice sublimates (muda diretamente de sólido para gás) at –78.5 °C, it can keep goods ultra cold without leaving moisture or residue. Traditional ice packs, por contraste, rely on water freezing at 0 °C and melt into liquid as they warm. The ultra cold temperature of dry ice sheets allows perishable items like vaccines, biologics and frozen seafood to remain well below freezing for days, making them ideal for long distance shipping.
Explicação expandida
Unlike rigid bricks or loose pellets, flexible sheets conform to the shape of the product, improving contact and reducing dead air space. To prepare a dry ice sheet, the super absorbent polymer cells are hydrated with water and then frozen. When exposed to warmer temperatures, Gelo seco sublimados, absorbing heat at a rate of 571 kJ per kilogram. This endothermic reaction maintains a cold environment without creating liquid water, preventing soggy packaging and eliminating cross contamination concerns. Standard gel packs melt at 0 °C and release water, while phase change materials may maintain more moderate temperatures (por exemplo, 2–8 °C or –20 °C) but cannot reach the –78.5 °C range of dry ice. Because flexible dry ice sheets maintain such low temperatures, they are especially useful for shipping mRNA vaccines, biologic samples and frozen desserts that must remain far below freezing.
Comparing dry ice sheets, Pacote de gel e PCMS
| Meio de resfriamento | Typical temperature range | Regulatory classification | Residue after use | Best use cases | Real world impact |
| Flexible dry ice sheet | –78.5 °C to –20 °C; can hold ultra cold temperatures for 24–72 hours | Aula 9 materiais perigosos; requires UN 1845 labeling and special handling | Sublimates directly to CO₂ gas, não deixando resíduos líquidos | Frozen pharmaceuticals, Biologics, specialty seafood | Keeps products well below freezing; no moisture contamination |
| Pacote de gel | 0 °C a 5 °C; moderate cooling for 12–48 hours | Non hazardous; fácil de manusear | Derrete na água, requiring leak proof packaging | Produção fresca, kits de refeições, short haul shipments | Provides mild cooling but not ultra cold temperatures |
| Phase change material (PCM) folha | –20 °C to –70 °C; stable temperature band for 24–72 hours | Often non hazardous because PCMs are non toxic | Typically no residue; PCMs absorb heat during phase transitions | Biologics requiring strict 2–8 °C or –20 °C ranges | Offers reusable, narrow band temperature control without dry ice gas |
Practical tips and recommendations
For ultra cold shipments: Use flexible dry ice sheets when your cargo must remain below –20 °C for more than a day. The sublimation of dry ice delivers powerful cooling while avoiding liquid leakage.
For moderate cold conditions: Gel packs are inexpensive and simple to use for perishable foods that require refrigeration rather than freezing.
For precise temperature ranges: PCM sheets are ideal when regulatory requirements demand a tight temperature band (por exemplo, 2–8 ° C.). They are often classified as non hazardous, reducing compliance burdens.
Exemplo do mundo real: A biotech company shipping mRNA vaccines used flexible dry ice sheets that wrapped around each vial, maintaining –75 °C for 72 hours despite external temperatures reaching 25 °C. Because the sheets sublimated rather than melted, the vials arrived completely dry and uncontaminated.
How do you size and apply flexible dry ice pack sheets for maximum effectiveness?
Direct answer and core guidelines
Choosing the right sheet thickness and layering method is essential for maintaining target temperatures during transit. The rule of thumb is to match the weight of dry ice to the weight of the product (um 1:1 ratio) and to select sheet thickness based on transit time. Por exemplo, um 12 mm sheet typically preserves ultra cold temperatures for up to 24 horas, um 18 mm sheet lasts about 48 horas, e a 24 mm sheet can sustain frozen temperatures for up to 72 horas. When layering, the sheet should fully wrap around the product or be sandwiched between layers of goods and insulation.
Expanded explanation and sizing details
Dry ice sheets come in various thicknesses and sizes. Because sublimation happens on the surface, the rate of sublimation decreases when the sheet is insulated and when ambient temperature is lower. The following guidelines will help you size your sheet correctly:
Assess product sensitivity and transit duration: If your cargo must remain below –20 °C for 48 horas, choose an 18 mm sheet. Para 72 horas, opt for a 24 mm sheet or multiple 18 mm sheets layered together.
Calculate dry ice weight: Determine the weight of the product and match it with an equivalent weight of dry ice. Por exemplo, um 5 kg box of frozen seafood would require approximately 5 kg of dry ice in sheet form.
Prepare the sheet properly: Hydrate the polymer cells evenly before freezing. This step ensures uniform sublimation and prevents brittle spots. Pre chill the product and insulated container to reduce the thermal load on the sheet.
Camada estrategicamente: For long hauls, wrap the product entirely with the sheet (full wrap method) or place sheets on the top and bottom with the product in between (sandwich method). This ensures consistent contact and reduces temperature gradients.
Seal and insulate: Use vented insulated containers to allow CO₂ gas to escape while retaining cold air. Combine the sheet with vacuum insulated panels or expanded polystyrene foam for better thermal performance.
Sizing guidelines table
| Transit duration | Recommended sheet thickness | Approximate dry ice weight (kg) per kg of product | Practical significance |
| Até 24 horas | 12 mm flexible dry ice sheet | 1 kg dry ice per 1 kg product | Suitable for overnight shipments such as next day pharmaceuticals; ensures product remains below –20 °C for one day. |
| 24–48 horas | 18 mm sheet or two 12 mm layers | 1–1.5 kg dry ice per kg product | For two day deliveries and international flights; layering provides redundant cooling. |
| 48–72 horas | 24 mm sheet or combination of three 12 mm sheets | 2 kg dry ice per kg product | Extended transit for vaccines and cell therapies; multiple layers maintain –75 °C for three days. |
Tips for specific scenarios
Laboratory samples: Label each specimen bag separately and wrap with a flexible sheet to avoid cross contamination. Place absorbent pads underneath to capture any condensation from the outer environment.
Meal kit services: Pre freeze food items, then wrap them with an 18 mm sheet and place additional sheets on top. The flexible nature of the sheet allows it to conform to irregular shapes (por exemplo, whole fish or stacked steaks), ensuring uniform cooling.
Pharmaceutical distribution: Use a 24 mm sheet for high value biologics that must remain below –70 °C. Employ real time temperature sensors embedded in the sheet to monitor conditions during transit.
Caso real: A meal kit company switched from rigid dry ice blocks to flexible sheets. By fully wrapping each food parcel with a 12 mm sheet and pairing it with an insulated liner, the company reduced total dry ice usage by 20 % while still maintaining –18 °C for 48 horas. Customer satisfaction improved as packages arrived dry and intact.
What safety and regulatory considerations apply to flexible dry ice sheets?
Direct answer and core requirements
O gelo seco é classificado como uma classe 9 hazardous material under international air transport (AQUI ESTÁ PI954) and U.S. Departamento de Transporte (PONTO) regulamentos. Every package containing dry ice must display the proper shipping name “Carbon dioxide, sólido "ou" gelo seco,” the United Nations number UN 1845, e o peso líquido do gelo seco. Hazard labels must be at least 100 mm on each side, and the total weight of dry ice per shipment must not exceed 200 kg. Flexible sheet formats do not change these requirements; they simply influence handling and packaging practices.
Expanded explanation of safety practices
Sublimation of dry ice produces CO₂ gas, which can displace oxygen in enclosed spaces and pose a suffocation hazard. To handle flexible dry ice sheets safely:
Wear personal protective equipment: Always use insulated gloves and eye protection when handling dry ice sheets. Avoid touching the sheets with bare skin to prevent frostbite.
Provide adequate ventilation: Use vented containers or shipping boxes with pressure relief valves so that CO₂ gas can escape. Do not seal dry ice inside airtight containers or plastic bags.
Label correctly: Afixado da classe 9 hazard label and note the net weight of dry ice. Include orientation arrows to indicate the correct upright position.
Follow shipper limits: Airlines and couriers may impose additional restrictions; por exemplo, some carriers limit dry ice shipments to 10 kg per package for passenger aircraft. Always consult the latest IATA and DOT guidelines.
Dispose responsibly: Let remaining dry ice sublimate in a well ventilated area away from children and pets. Do not flush dry ice down the drain or place it in a trash compactor. Once sublimated, the polymer sheet can be recycled according to local regulations.
Training and documentation: Because dry ice is hazardous, personnel should complete basic hazardous material training. Documents must accompany shipments, stating the net weight and proper shipping name. For PCMs and certain gel packs, the non hazardous classification reduces training and paperwork.
Compliance checklist table
| Exigência | Detalhes | Importância |
| Proper shipping name and UN number | Label packages as “Carbon dioxide, sólido "ou" gelo seco,” and include UN 1845. | Avoids fines and ensures regulatory compliance. |
| Net weight declaration | Record the weight of dry ice on the package (por exemplo, 5 kg). | Enables carriers to verify limits and plan ventilation. |
| Aula 9 Etiqueta de perigo | Use a diamond shaped label measuring at least 100 mm per side with hazard symbol and number. | Alerts handlers to potential hazards. |
| Ventilação | Use vented packaging to allow CO₂ gas to escape. | Prevents pressure buildup and suffocation. |
| Equipamento de proteção pessoal (EPI) | Wear insulated gloves and eye protection when handling sheets. | Prevents frostbite and injury. |
| Training and documentation | Employees handling dry ice must be trained in hazardous materials. | Ensures safe handling and compliance. |
Exemplo do mundo real: Em 2024 a pharmaceutical distributor mistakenly sealed dry ice sheets inside an airtight plastic wrap. CO₂ gas built up, rupturing the packaging and delaying the shipment. After adopting vented insulated boxes and proper labeling, the company achieved 100 % compliance and avoided further delays.
How do flexible dry ice sheets fit into sustainability and market trends for 2025?
Market dynamics and supply challenges
The dry ice market is experiencing rapid growth due to booming demand in food delivery, vaccine distribution and industrial processes. Global consumption of dry ice increased about 5 % annually between 2021 e 2024, while supply expanded only 0.5 % per year, creating a shortage. This imbalance drove dry ice prices up by as much as 300 % in some regions. The dry ice market was valued at roughly USD 1.54 bilhão em 2024 and is projected to reach USD 2.73 bilhão por 2032. To manage these pressures, manufacturers are investing in local production hubs, capturing CO₂ from industrial exhaust, and exploring hybrid cooling solutions that combine dry ice with PCMs or vacuum insulation. Improved insulation reduces sublimation losses from 8 % per day down to 3 %, allowing shippers to use less dry ice while achieving the same performance.
Sustainable materials and smart technology
Environmental concerns and regulatory pressure are driving innovation. Flexible dry ice sheets are increasingly made with recycled CO₂ and biodegradable polymers. New sustainable coatings reduce frost buildup and extend cooling performance. IoT enabled sheets embed temperature sensors that transmit real time data to a cloud dashboard, allowing shippers to detect excursions early. Other emerging technologies include:
Biodegradable coatings: Manufacturers apply plant derived coatings to dry ice cells to reduce sublimation rates and moisture ingress. These coatings break down naturally, avoiding microplastic pollution.
Sensores inteligentes: Low power Bluetooth or cellular sensors are integrated into the sheet to monitor temperature and location. When a temperature excursion occurs, an alert is sent to stakeholders for immediate action.
Customizable shapes: 3D forming technology allows dry ice sheets to be cut into specific shapes to fit custom packaging. This reduces wasted space and ensures even temperature distribution.
Hybrid systems: Combining dry ice sheets with PCMs or gel packs extends cooling duration while reducing the total amount of dry ice needed. Por exemplo, pairing a dry ice sheet with a –20 °C PCM extended the frozen state by 40 % in field tests.
Vacuum insulation panels (VIPs): VIPs drastically reduce heat transfer, enabling shippers to use thinner dry ice sheets. When integrated with smart sensors, VIPs can maintain temperature for several days even in warm climates.
Market and environmental insights table
| Trend or innovation | Descrição | Practical impact for users |
| Local CO₂ sourcing | Capturing CO₂ from fermentation, ammonia and ethanol plants for dry ice production. | Reduces dependence on fossil fuels and stabilizes supply, lowering costs. |
| Biodegradable polymers | Using compostable or recyclable materials for sheet casings. | Makes end of life disposal easier and appeals to eco conscious customers. |
| Monitoramento inteligente | Embedding temperature and location sensors in sheets. | Improves transparency, reduces product loss and enables real time interventions. |
| Sistemas de resfriamento híbrido | Combining dry ice sheets with PCMs or gel packs to optimize temperature control. | Reduces dry ice consumption, lowers costs and eases regulatory burden. |
| Isolamento aprimorado | Adoption of vacuum insulation panels and reflective liners. | Cuts sublimation loss from 8 % para 3 % por dia, allowing lighter packages. |
Market story: Facing a CO₂ shortage in 2023–2024, a seafood exporter in the Pacific Northwest installed a CO₂ capture unit at a nearby brewery to produce dry ice locally. By coupling the locally sourced dry ice with upgraded insulation and smart sensors, the company kept shipments below –30 °C for 60 hours while cutting dry ice use by 30 %.
2025 innovations and future outlook for flexible dry ice sheets
Overview of emerging technologies and trends
The future of flexible dry ice sheets lies in the intersection of material science, digitalization and regulation. Em 2025 e além, Espere ver:
Advanced PCMs integrated with dry ice: Some manufacturers embed PCMs within dry ice cells. Quando o gelo seco sublima, the PCM takes over, maintaining a stable temperature band for another day. This hybrid design extends shipping windows and simplifies regulatory compliance.
AI driven logistics: Machine learning algorithms analyze real time sensor data to optimize routing, predict sublimation rates and automatically adjust shipment parameters. This reduces waste and improves on time delivery.
CO₂ neutral certifications: Companies that source CO₂ from waste streams and use biodegradable sheets can obtain CO₂ neutral certifications, appealing to environmentally conscious consumers.
Harmonização regulatória: Aviation authorities are exploring revised guidelines that differentiate between traditional dry ice blocks and flexible sheets. The aim is to reduce unnecessary paperwork without compromising safety.
3D printed custom liners: 3D printing enables shippers to produce custom fitted insulation and sheet holders, improving contact and reducing void space.
Progress summary list
Biodegradable dry ice sheets are moving from pilot trials to mainstream adoption, allowing composting or recycling after use.
Sensor enabled sheets are now commercially available, sending temperature, humidity and location data to centralized dashboards.
Hybrid ice/PCM solutions are predicted to reduce dry ice usage by 40 % por 2026 through improved heat management and extended duration.
Market growth: Analysts forecast the global dry ice and alternative refrigerant market to grow from USD 1.54 bilhão em 2024 para USD 2.73 bilhão por 2032.
Market insights for decision makers
Cold chain suppliers should monitor regulatory developments around hazardous materials. As PCMs and biodegradable sheets gain traction, carriers may adjust weight limits and labeling requirements. Investing in IoT enabled packaging solutions can provide immediate return on investment through reduced spoilage and improved compliance. Finalmente, diversifying refrigerant options – combining dry ice with PCMs and improved insulation – will mitigate supply chain risks and control costs.
Perguntas frequentes
Q1: How long do flexible dry ice pack sheets last?
A properly sized dry ice sheet can maintain ultra cold temperatures for 24–72 hours. Duration depends on sheet thickness (12 mm for one day, 18 mm for two days, e 24 mm for three days) and on how well the package is insulated.
Q2: Can flexible dry ice sheets be reused?
Não. Uma vez que o gelo seco sublimado, the sheet no longer provides cooling. No entanto, the polymer casing may be recyclable depending on local regulations. For reusable options, consider PCM sheets or gel packs.
Q3: How do you dispose of flexible dry ice sheets safely?
Allow any remaining dry ice to sublimate in a well ventilated area away from children and pets. Do not dispose of dry ice in a sink or trash compactor. Once sublimated, dispose of or recycle the polymer casing according to municipal guidelines.
Q4: Are flexible dry ice sheets safe for air transport?
Sim, but they are subject to IATA PI954 regulations. Packages must display the “Dry ice” or “Carbon dioxide, solid” label, E 1845 identification, e peso líquido. Ventilation and weight limits (tipicamente 200 kg per shipment) must be respected.
Q5: What is the difference between flexible dry ice sheets and PCM sheets?
Dry ice sheets use solid CO₂ that sublimates at –78.5 °C, delivering ultra cold temperatures. PCM sheets use substances that change phase at specific temperatures (por exemplo, –20 °C or 5 °C) and are often non hazardous. PCMs provide precise temperature control and are reusable.
Resumo e recomendações
Takeaways -chave
Flexible ice dry ice sheets are thin, moldable blankets that can maintain temperatures as low as –78.5 °C for up to 72 horas, making them ideal for vaccines and biologic shipments.
Proper sizing and layering are critical: usar 12 mm sheets for 24 hour trips, 18 mm para 48 horas e 24 mm para 72 horas. Match the weight of dry ice to the product weight and use vented, recipientes isolados.
Safety and compliance cannot be overlooked. Dry ice is a Class 9 materiais perigosos, requiring UN 1845 rotulagem, net weight declaration and proper ventilation.
Market dynamics show rapid growth and supply shortages, prompting investments in local CO₂ production, sustainable materials and hybrid refrigerant systems.
Emerging innovations such as biodegradable coatings, IoT sensors and hybrid ice/PCM solutions are transforming cold chain logistics and will likely reduce dry ice usage by up to 40 % in coming years.
ACTO ACEDIVO PRÓXIMO PASSOS
Assess your product’s thermal requirements: Determine the required temperature range and transit duration to choose between dry ice sheets, PCMs or gel packs. Use the sizing guidelines provided above.
Invest in proper packaging: Use remetentes isolados, vacuum insulation panels and vented lids to reduce sublimation and ensure compliance.
Treine sua equipe: Provide hazardous materials training for anyone handling dry ice. Implement checklists for labeling, ventilation and disposal.
Explore smart solutions: Consider adopting IoT enabled dry ice sheets and hybrid PCM/dry ice systems to improve visibility and extend shipping windows.
Mantenha -se informado sobre regulamentos e inovações: Monitor IATA and DOT updates and evaluate new sustainable materials and technologies as they emerge.
Sobre Tempk
We are a leading provider of cold chain packaging solutions, specializing in flexible dry ice sheets, phase change materials and insulated shipping systems. Our team combines decades of experience in the biotechnology, pharmaceutical and food industries to design solutions that meet stringent temperature requirements while minimizing environmental impact. We pride ourselves on our innovative products—such as biodegradable dry ice sheets and sensor enabled packaging—that empower customers to ship temperature sensitive goods safely and sustainably. By partnering with us, you gain access to expert advice, high quality refrigerants and a global network of distribution centers.
Need help designing the perfect cold chain solution? Contact our specialists today for a personalized consultation and discover how Tempk can keep your products safe from the factory to the final destination.
