How Does a Sublimation Dry Ice Pack Work and Why Do You Need One?
Dry ice is unique because it doesn’t melt like water ice; sublima, turning straight from solid carbon dioxide into gas. UM sublimation dry ice pack harnesses this property to keep shipments ultra cold without leaving meltwater. If you ship vaccines, frutos do mar, gourmet meats or lab samples, you’ll need a cooling solution that maintains –78.5 °C (–109.3 °F) and prevents moisture damage. This article explains how sublimation dry ice packs function, how to choose the right type, safe handling practices and 2025 tendências. You’ll learn to calculate the right quantity, compare alternatives like gel packs and phase change materials, and stay compliant with regulations. Let’s explore how these packs can protect your products and improve your cold chain strategy.
What a sublimation dry ice pack is and why it beats regular ice packs for ultra cold shipments.
How pellets, pack sheets and gel sheets differ in temperature range and duration.
Step by step instructions for safe packing, labelling and compliance.
Formulas to determine how many packs you need and tips to reduce sublimation.
Comparisons with gel packs and phase change materials, including cost and sustainability.
Emerging trends in 2025: reusable packs, Captura de CO₂, hybrid cooling and smart sensors.
What Is a Sublimation Dry Ice Pack and How Does It Work?
Resposta direta
UM sublimation dry ice pack is a cooling device made from solid carbon dioxide (Co₂) enclosed in a protective outer shell. When exposed to warmer temperatures, dry ice sublimates at –78.5 °C (–109.3 °F), meaning it transitions directly from solid to gas without a liquid phase. This process absorbs heat from the surrounding environment and keeps goods frozen or near frozen. Because there is no meltwater, fragile vaccines, cell cultures or seafood remain dry and undamaged. The gas escapes through vented packaging, so pressure doesn’t build up. Sublimation dry ice packs are essential for shipments requiring temperatures below –20 °C and durations beyond what gel packs can handle.
Explicação expandida
Understanding why dry ice sublimation is different from melting helps you choose the right cold chain solution. Water ice melts at 0 °C (32 °F) and produces liquid water, which can damage packaging and dilute vaccines or spoil seafood. Gelo seco é sólido co₂, and its sublimation temperature is –78,5 ° C. (–109.3 °F). When it absorbs heat, it changes directly into CO₂ gas, não deixando água para trás. This property allows dry ice packs to maintain extremely cold conditions for 24–72 hours, depending on insulation and pack size. The outer shell of a sublimation dry ice pack prevents direct contact with the cargo and slows down the sublimation rate. In gel sheet dry ice packs, a flexible gel layer surrounds the dry ice core, slowing sublimation and distributing cold evenly. The protective shell makes handling safer and reduces CO₂ exposure while the gas escapes through vent holes, ensuring your shipment stays dry and at the right temperature.
Components and Types of Sublimation Dry Ice Packs
Different sublimation dry ice packs exist to match shipment size and duration. The main formats are Pellets, pack sheets e gel sheet packs. The table below compares them with traditional gel packs and phase change materials (PCM) used in cold chain logistics:
| Método de resfriamento | Faixa de temperatura | Duração típica | O que isso significa para você |
| Pelotas de gelo seco | –78,5 ° C. | 24–48 horas | Provide immediate flash freezing for vaccines and biotech samples; require protective gear and ventilation due to rapid sublimation |
| Folhas de embalagens de gelo seco | –40 °C to –60 °C | 36–72 horas | Offer gradual cooling and longer hold times; reusable and easier to handle; minimize CO₂ exposure |
| Gel Sheet Dry Ice Packs | –78.5 °C to –20 °C | 24–48 horas | Combine a dry ice core with a gel layer that slows sublimation and distributes cold evenly |
| Pacotes de gel (Water Based) | 0 °C to –20 °C | 12–24 horas | Suitable for chilled goods; reusable and inexpensive, but not cold enough for frozen shipments |
| Phase Change Materials (PCM) | Personalizável (2–8 ° C., –20 °C, etc.) | 24–96 hours | Maintain stable temperatures without being hazardous; initial cost is higher but packs are reusable and easier to comply with regulations |
Practical tips and suggestions for users
Vaccine shipments: Use pellet based sublimation dry ice packs in high performance vacuum insulated shippers. Vaccines often require temperatures below –70 °C; pellets deliver rapid cooling and, when combined with insulation, keep vials stable for 48 horas.
Frozen seafood and meat: Choose pack sheets or gel sheet packs for –29 °C to –40 °C shipments lasting two to three days. These packs are reusable, reduce CO₂ exposure and minimize freezer burn.
Hybrid cooling for long routes: For shipments exceeding 72 horas, combine pellets, pack sheets and PCM. A hybrid setup layers pellets at the bottom, pack sheets around the cargo and PCM on top; this can extend hold time by 25 % and reduce dry ice consumption by about 18 %.
Real world case: A biotech firm shipping mRNA vaccines uses 8 kg of dry ice pellets at the bottom of a 30 L vacuum insulated shipper, two 24 cell dry ice sheets around the vials and PCM packs on top. This hybrid system maintains temperatures below –70 °C for 60 hours and cuts dry ice usage by roughly 20 % compared with pellets alone.
How to Use Sublimation Dry Ice Packs Safely and Comply With Regulations?
Resposta direta
Dry ice packs are safe when handled correctly, but they can cause frostbite, asphyxiation or explosions if misused. Always wear insulated gloves and eye protection. Use vented, well insulated containers to allow CO₂ gas to escape and prevent pressure buildup. Label packages with “Dry Ice” or “Carbon Dioxide, Sólido,” include the net weight and UN 1845 hazard identifier. Siga IATA PI 954 and DOT guidelines: passenger aircraft often restrict dry ice to 2.5 kg por pacote, while cargo flights allow up to 200 kg.
Explicação expandida
Solid CO₂ poses three primary hazards: asfixia, Frostbite e explosion. Sublimation produces CO₂ gas, que pode deslocar o oxigênio em espaços confinados; always handle dry ice in well ventilated areas and never store it in closed refrigerators or vehicles. At –79 °C, skin contact causes severe frostbite almost instantly, so use insulated gloves, goggles and long sleeves. The expansion ratio of dry ice is 1:554; sealing it in airtight containers can cause them to burst. Use insulated shippers with vent holes, pre condition containers to reduce thermal shock and layer pellets or pack sheets correctly. For shipments, mark packages with hazard labels and emergency contact numbers. Only trained personnel should handle dry ice shipments, and emergency response information must accompany the package.
Step by step packing process
Preparação: Hydrate reusable pack sheets (se aplicável) by soaking them and freezing flat. Freeze your product to the desired temperature before packing.
Pre chill the container: Place the insulated box in a freezer or pre chill it with gel packs. Pre conditioning can reduce sublimation by up to 15 %.
Camada inferior: Add the required amount of pellets or a pack sheet at the bottom.
Buffer: Place a cardboard or foam layer over the dry ice to prevent direct contact with your product and avoid freezer burn.
Carregar produto: Insert your items, filling voids with cushioning material to prevent warm air pockets.
Camada superior: Add more pack sheets or pellets on top to maintain uniform temperature.
Vent and close: Ensure the container is vented and close the lid without sealing it airtight.
Rotule e documento: Attach hazard labels, note the net weight of dry ice and include emergency contact information.
Sugestão
Ventilation matters: Do not place dry ice in passenger compartments. Transport it in the trunk or cargo area with windows slightly open to allow CO₂ gas to escape.
Equipamento de proteção pessoal: Always handle dry ice with insulated gloves, goggles and tongs. Children should not handle dry ice, and adults should supervise disposal.
Disposição: Let leftover dry ice sublimate in a well ventilated area. Never dispose of it in sinks or waste bins, as extreme cold can crack surfaces.
Caso real: A laboratory forgot to vent its cooler during a genetic sample shipment, causing pressure from sublimating dry ice to burst the lid. Proper venting and buffer layers would have prevented this incident.
How Many Sublimation Dry Ice Packs Do You Need? Sizing Formulas and Practical Tips
Resposta direta
Accurately sizing your sublimation dry ice packs ensures frozen shipments stay cold without waste. UM common rule is to allocate 5–10 kg of dry ice per 100 L of insulated volume for each 24 hour period. For pellet packs, this translates to about 5–10 lb per day for small parcels. Pack sheets provide roughly 8–12 hours of cooling per 24 cell sheet. Pre chilling the container and filling voids with dunnage can reduce sublimation by 15 %. Use a sizing worksheet or online calculator to match dry ice weight to container size, shipment duration and insulation quality.
Explicação expandida
Sizing depends on container volume, qualidade de isolamento, temperatura externa e Duração da remessa. Por exemplo, um 10 L insulated box might need 0.75–1 kg of pellets or one sheet for around 12 horas. UM 40 L container might require 4–5 kg of pellets and 4–5 sheets to maintain –29 °C to –40 °C for 48–72 hours. In warm weather, increase dry ice quantity because high external temperatures accelerate sublimation. Better insulation reduces heat ingress; upgrading from expanded polystyrene (EPS) to vacuum insulated panels (VIP) can cut dry ice consumption by 10–25 %. Hybrid setups combining dry ice and PCM can further extend hold time and reduce CO₂ usage by about 18 %.
Practical tips and suggestions for users
Match duration to transit time: Calculate how long the shipment will be in transit, including potential delays, and add a safety margin.
Account for insulation quality: Invest in high performance containers; reused boxes degrade and increase sublimation rates.
Use a calculator: Provide an interactive sizing tool on your website so customers can input volume, duration and insulation type to calculate recommended dry ice weight and sheet count.
Exemplo do mundo real: A seafood exporter shipping 20 kg of frozen tuna overseas uses a 40 L insulated cooler with 5 kg of pellets, four pack sheets and vacuum insulated liners. Depois 48 hours the shipment arrives at –29 °C and uses 15 % less dry ice by pre chilling the cooler and filling voids.
Comparing Sublimation Dry Ice Packs with Gel Packs and PCM Solutions
Resposta direta
While dry ice packs provide ultra cold conditions, they are not always the best solution. Pacotes de gel work well for chilled shipments (2–8 ° C.) and are reusable and inexpensive. Phase change materials (PCM) maintain stable temperature ranges without hazardous classification and are ideal for biopharma kits requiring 2–8 °C or –20 °C. The choice depends on target temperature, duração, regulatory complexity and budget. Dry ice is ideal for frozen goods that must remain below –20 °C; PCM is better for controlled room temperature (CRT) or refrigerated goods; gel packs suit local deliveries.
Explicação expandida
Dry ice sublimates at –78.5 °C, producing ultra cold conditions but requiring hazardous materials training and labelling. Pacotes de gel, por contraste, congelar em 0 °C, making them suitable for chilled goods but not for deep frozen products. Gel packs are reusable and affordable but provide only 12–24 hours of cooling. PCM packs use engineered materials that melt and solidify at specific temperatures (por exemplo, 2–8 °C or –20 °C); they are reusable, have longer hold times and avoid HAZMAT restrictions. No entanto, PCMs require pre conditioning and cost more upfront. When choosing, consider shipment duration, requisitos de temperatura, regulatory burden and sustainability. A hybrid solution combining dry ice and PCM can deliver rapid cooling and long term stability.
Practical tips and suggestions for users
Short chilled shipments: For local deliveries or goods that must remain between 2–8 °C, use gel packs. They are reusable and non hazardous.
Temperature stability: For biologics needing 2–8 °C or –20 °C, choose PCM packs. They offer precise temperature control and avoid HAZMAT restrictions.
Ultra cold goods: Use sublimation dry ice packs for vaccines, frozen seafood and gene therapies requiring –70 °C or colder. For shipments lasting beyond 72 horas, combine dry ice with PCM and high performance insulation to extend duration.
Caso real: A gene therapy company shipped ultra cold payloads using validated dry ice shippers and hazard training. With proper packouts, shipments cleared customs with zero HAZMAT issues.
2025 Trends and Innovations in Sublimation Dry Ice Packaging
Visão geral da tendência
The sublimation dry ice pack industry is evolving rapidly due to supply constraints, sustainability concerns and technological advancements. Demand for dry ice is growing about 5 % per year, whereas carbon dioxide supply grows only 0.5 %, causing periodic shortages and price spikes up to 300 %. The global dry ice market was valued at $1.54 bilhão em 2024 and is projected to reach $2.73 bilhão por 2032. Em resposta, manufacturers are building localized production hubs and investing in on site CO₂ capture. Format selection is critical: large blocks sublimate slowly; pellets deliver rapid cooling but vaporize faster; thin slices fit neatly into packaging and minimize voids. Proper container design, pre conditioning and minimizing void space reduce sublimation to 3–8 % por dia. Mistakes such as poor venting or leaving warm pockets accelerate sublimation and compromise product integrity.
Último progresso em um olhar
CO₂ Capture & Recovery: Companies are sourcing carbon dioxide from renewable processes like bioethanol fermentation to produce dry ice, creating a circular supply and reducing emissions.
Reusable Pack Sheets: Durable dry ice sheets can be refrozen multiple times, lowering waste and cost.
Hybrid Packouts: Combining dry ice with PCMs and high performance insulation reduces CO₂ consumption by about 18 % and extends hold times.
Sensores inteligentes & IoT Tracking: Real time monitoring of temperature and CO₂ levels reduces spoilage and ensures compliance. Industry studies show that IoT tracking cuts product excursions by 30 % and dry ice consumption by 18 %.
Biodegradable & Embalagem reciclável: Companies are adopting sustainable packaging materials to minimize waste and meet environmental regulations.
Automação & Robotics: Automated storage and retrieval systems are being adopted in cold warehouses; sobre 80 % of warehouses lack automation, so robotics improves efficiency and reduces labour costs.
End to End Visibility: IoT devices provide real time insights into temperature, location and humidity, enabling route optimization and reducing spoilage.
Insights de mercado
Rising demand for biologics and gene therapies—about 20 % of new drugs require ultra cold storage—is driving growth in the pharmaceutical cold chain. The North American food cold chain market is projected to reach $86.67 bilhão por 2025, and sustainable logistics practices are essential to reduce food waste and align with consumer expectations. As supply shortages persist, companies should secure long term dry ice contracts or invest in localized pelletizer units. Embracing renewable CO₂ sources, reusable packs and smart monitoring will help businesses adapt to market volatility and regulatory pressure.
Perguntas frequentes
Q1: How long does a sublimation dry ice pack last?
Dry ice packs typically keep shipments frozen for 24–48 horas, depending on pack format, insulation quality and external temperature. Pack sheets may extend cooling up to 72 horas, while hybrid setups can reach 60 horas ou mais.
Q2: Can you reuse a sublimation dry ice pack?
Pellet based packs are single use; they sublimate completely. No entanto, pack sheets encasing pellets are designed for reuse and can be refrozen multiple times. Always inspect reusable packs for damage before reuse.
Q3: What safety precautions should I take when handling dry ice?
Use luvas isoladas e proteção para os olhos, handle dry ice in well ventilated spaces and never seal it in airtight containers. Follow IATA and DOT regulations for shipping and labelling.
Q4: How much dry ice should I use for my shipment?
A simple rule is 5–10 kg of dry ice per 100 L of container volume per 24 horas. Adjust based on insulation quality, external temperature and shipment duration.
Q5: What’s the difference between a sublimation dry ice pack and a gel pack?
Sublimation dry ice packs maintain ultra cold temperatures (–78,5 ° C.) and produce no water. Gel packs freeze around 0 °C and are better for chilled shipments. Gel packs are reusable and non hazardous, while dry ice packs require hazard labels and training.
Q6: Are sublimation dry ice packs environmentally friendly?
Dry ice itself is made from recycled CO₂; no entanto, its use releases CO₂ back into the atmosphere and requires energy for production. Sustainability initiatives include CO₂ capture and reuse, reusable pack sheets, hybrid cooling e embalagem biodegradável. Choosing suppliers who capture CO₂ from renewable sources and adopting reusable packs can reduce environmental impact.
Summary and Suggestion
In cold chain logistics, sublimation dry ice packs provide unmatched ultra cold performance for vaccines, seafood and lab samples. They sublimate at –78.5 °C, maintaining deep freeze temperatures without water damage. Pellets deliver rapid cooling for short durations; pack sheets and gel sheets extend hold times and can be reused. Safe handling is critical: use insulated gloves, vented containers and hazard labels. Proper sizing—5–10 kg per 100 L per day—prevents temperature excursions. Hybrid packouts combining dry ice, PCM and high quality insulation reduce CO₂ usage and extend hold time. Finalmente, staying informed about 2025 trends—CO₂ capture, reusable packs and IoT monitoring—helps you optimize cost, sustainability and reliability.
Sugestão
Assess your needs: Determine the required temperature range, shipment duration and container volume.
Choose the right pack format: For ultra cold shipments, select pellet or pack sheet dry ice packs; for chilled goods, consider gel packs or PCM.
Calculate and pre condition: Use the sizing formulas (5–10 kg per 100 L per 24 horas) and pre chill containers to reduce sublimation.
Follow safety protocols: Wear PPE, ensure ventilation and comply with IATA and DOT labelling requirements.
Invest in sustainability: Adopt reusable pack sheets, hybrid cooling and smart sensors to lower costs and environmental impact.
Sobre Tempk
We are Tempk, a leader in cold chain packaging solutions. Our products include sublimation dry ice packs, pacotes de gel, PCM packs and insulated containers. We leverage renewable CO₂ sources and advanced insulation to deliver reliable, sustainable cooling. Our team of cold chain specialists provides training, hazard labelling, and regulatory guidance. By partnering with us, you gain access to validated pack designs, IoT monitoring and custom calculators that simplify complex logistics. Whether shipping vaccines or gourmet foods, we help you keep them at the right temperature.
Ação
Ready to optimize your cold chain? Contact Tempk’s experts for a personalized consultation and access to our calculator tool. We’ll help you choose the right sublimation dry ice pack, design hybrid solutions and stay ahead of 2025 tendências.
