Shipping with Dry Ice: What You Need to Know

Why Ship with Dry Ice?

Shipping perishable items presents unique challenges, particularly when traditional refrigeration isn't available or practical. Dry ice (solid carbon dioxide) offers an effective solution for maintaining extremely cold temperatures during transit without the mess of melting ice or the complexity of powered refrigeration units.

At -78.5°C (-109.3°F), dry ice provides a significantly colder environment than regular ice, making it ideal for shipping:

• Frozen food products
• Biological samples and medical specimens
• Pharmaceuticals requiring deep freezing
• Specialty desserts like ice cream
• Temperature-sensitive chemicals
• Vaccines and other medical supplies

However, shipping with dry ice isn't as simple as placing it in a box with your items. As a hazardous material (classified as UN1845, Class 9), dry ice is subject to specific regulations and handling requirements that vary by carrier and destination. This guide will walk you through the essential considerations for successful dry ice shipping.

Carrier Regulations: What You Need to Know

Each shipping carrier has specific requirements for packages containing dry ice. Here's what you need to know about the major carriers:

USPS (United States Postal Service)

USPS has the most restrictive policies regarding dry ice shipments:

• Limited to domestic mail only (no international shipments)
• Maximum of 5 pounds of dry ice per package
• Only permitted in Priority Mail, Priority Mail Express, or First-Class Package Service
• Must be clearly marked as containing dry ice
• Requires proper ventilation to allow CO₂ gas to escape
• Cannot be dropped in collection boxes; must be handed to a postal employee

UPS (United Parcel Service)

UPS allows dry ice shipments with the following requirements:

• Accepts both domestic and international shipments
• Requires a UPS Hazardous Materials Contract for regular shippers
• Packages must be properly labeled with a Class 9 hazard label
• Maximum weight limits vary by service type and destination
• Requires a completed Shipper's Declaration for Dangerous Goods for air shipments
• Packaging must allow for proper ventilation

FedEx

FedEx has detailed guidelines for dry ice shipments:

• Accepts both domestic and international shipments
• Requires proper Class 9 hazard labeling
• For air shipments, requires a completed Shipper's Declaration for Dangerous Goods
• For ground shipments, requires proper marking but not a full declaration
• Packaging must allow for proper ventilation
• Offers specialized cold shipping solutions for regular shippers

DHL

DHL handles dry ice shipments with these requirements:

• Specializes in international shipments
• Requires advance notification for dry ice shipments
• Packages must display proper hazard labeling
• Requires a completed Shipper's Declaration for Dangerous Goods
• Has country-specific regulations for international destinations
• May require additional documentation for certain destinations

Proper Packaging for Dry Ice Shipments

Effective packaging is critical for dry ice shipments to maintain temperature, ensure safety, and comply with regulations. Here's how to properly package items with dry ice:

Outer Packaging Selection

The outer container should be:

• Sturdy and rigid - Corrugated cardboard boxes are acceptable, but they should be high-quality with good crush resistance
• Well-insulated - Styrofoam coolers or specialized insulated shipping containers work best
• Properly sized - Allow room for the product, dry ice, and insulation without being too large
• New or like-new condition - Avoid reused boxes that may have weakened structural integrity
• Free of prior hazard markings - Don't reuse boxes with old hazard labels

Inner Packaging Considerations

For the contents and dry ice:

• Separate the product from direct contact with dry ice - Use barriers like cardboard, paper, or cloth to prevent freezer burn
• Secure the contents - Prevent movement during transit with appropriate cushioning
• For liquid samples - Use leak-proof primary containers and absorbent materials
• For medical or biological specimens - Follow specific containment protocols (often requiring triple packaging)

Dry Ice Placement

How you position dry ice depends on your shipment needs:

• For top-loading packages - Place dry ice on top of the contents as CO₂ gas flows downward
• For surrounding cooling - Position dry ice blocks around the sides and top of the contents
• For longer transits - Use larger blocks rather than pellets as they sublimate more slowly
• For temperature-critical items - Consider using temperature monitoring devices

Step-by-Step Packaging Process

1. Prepare your item(s) for shipping, ensuring they're already cold before packing
2. Line your sturdy outer box with an insulating container (like a styrofoam cooler)
3. Place a barrier layer (cardboard, paper, cloth) where dry ice will contact the product
4. Position your pre-cooled items inside the container
5. Add the appropriate amount of dry ice (calculate based on transit time)
6. Place additional barrier material between dry ice and products if needed
7. Close the inner insulating container but do not seal it airtight
8. Fill any void spaces in the outer box with cushioning material
9. Close and secure the outer box with packing tape
10. Apply all required labeling (see next section)

Required Labeling and Documentation

Proper labeling is essential for regulatory compliance and handler safety. Here's what your dry ice package needs:

Mandatory Package Markings

• The words "Dry Ice" or "Carbon Dioxide, Solid"
• UN1845 identification number
• Net weight of dry ice in kilograms
• Shipper's name and address
• Recipient's name and address
• Class 9 hazard label (diamond with vertical stripes)

The markings should be durable, legible, and placed on a contrasting background on the outside of the package.

Documentation Requirements

For most carriers, you'll need:

• Shipping label with complete addresses
• For air shipments: Shipper's Declaration for Dangerous Goods (specific form varies by carrier)
• For international shipments: Commercial invoice and any destination-specific documentation
• For medical or biological specimens: Additional declarations or permits may be required

International Shipping Considerations

International shipments with dry ice involve additional complexities:

Country-Specific Regulations

Different countries have varying regulations regarding dry ice imports. Before shipping internationally:

• Verify that the destination country permits dry ice imports
• Check if there are quantity restrictions
• Determine if special permits are required
• Confirm if the contents being preserved with dry ice have any import restrictions

Documentation for Customs

International shipments require:

• Commercial invoice with detailed description of contents
• Harmonized System (HS) codes for the contents
• Value declaration for customs purposes
• Shipper's Declaration for Dangerous Goods (for air shipments)
• Any permits specific to the contents (especially for food, biological, or medical items)

Language Requirements

Some countries require hazard information in the local language in addition to English. Check with your carrier for specific requirements for your destination.

Cost Considerations

Shipping with dry ice involves several cost factors beyond standard shipping rates:

Direct Costs

• Dry ice purchase - Typically $1-3 per pound depending on quantity and location
• Insulated packaging - Specialized containers can cost $10-50 depending on size and quality
• Hazardous material handling fees - Carriers often charge $5-30 extra for dry ice shipments
• Expedited shipping - Often necessary due to dry ice sublimation

Indirect Costs

• Documentation preparation time - Especially for international shipments
• Training or certification - For regular shippers
• Potential for rejected shipments - If packaging or documentation is incorrect
• Insurance - Recommended for high-value temperature-sensitive items

Alternatives to Dry Ice Shipping

While dry ice is effective, it's not always the best option for every situation. Consider these alternatives:

Gel Packs and Ice Packs

Best for: Refrigerated (not frozen) items, shorter transit times

Advantages:

• No hazardous material restrictions
• Reusable in many cases
• No risk of CO₂ buildup
• Simpler packaging requirements

Limitations:

• Cannot achieve the extreme cold of dry ice
• Melts into liquid (potential for leakage)
• Shorter effective duration

Liquid Nitrogen Shipping

Best for: Ultra-low temperature requirements, biological samples

Advantages:

• Colder than dry ice (-196°C/-320°F)
• Longer-lasting for certain specialized containers
• Industry standard for certain biological materials

Limitations:

• More expensive
• Requires specialized dewars or cryogenic containers
• Stricter handling requirements
• More hazardous than dry ice

Insulated Shipping Containers

Best for: Pre-frozen items with short transit times

Advantages:

• No consumable cooling medium required
• Reusable
• No hazardous material concerns
• Environmentally friendly

Limitations:

• Only maintains temperature, doesn't actively cool
• Limited effective duration
• Not suitable for items requiring deep freezing

Professional Cold Chain Logistics

Best for: High-value shipments, regular shipping needs, pharmaceuticals

Advantages:

• Temperature-controlled throughout the entire journey
• Professional handling and monitoring
• Reduced risk of temperature excursions
• Often includes insurance and guarantees

Limitations:

• Significantly more expensive
• May have limited service areas
• Less flexible scheduling

Receiving Dry Ice Shipments

If you're expecting a package containing dry ice, follow these guidelines:

Safe Handling

• Wear insulated gloves when handling the package
• Open the package in a well-ventilated area
• Do not touch dry ice with bare skin
• Keep away from children and pets
• Do not place in airtight containers

Storage Considerations

• Remove contents promptly and transfer to appropriate storage
• If you need to store the dry ice itself:
  • Use an insulated container with a loose-fitting lid (never airtight)
  • Keep in a well-ventilated area
  • Do not store in a standard freezer
  • Do not store in confined spaces like closets or small rooms

Disposal Methods

To dispose of remaining dry ice:

• Allow it to sublimate in a well-ventilated area away from people and pets
• Never dispose of in trash, sink, toilet, or other drainage systems
• Never leave in an enclosed vehicle or room
• For larger quantities, consider placing outside in a secure, ventilated area

Finding Dry Ice for Shipping

When preparing to ship with dry ice, you'll need a reliable source. Consider these options:

• Grocery stores - Many larger supermarket chains sell dry ice
• Dry ice suppliers - Specialized companies offering various forms and quantities
• Shipping centers - Some UPS or FedEx locations sell dry ice for shipping
• Industrial gas suppliers - Companies like Airgas or Praxair
• Ice cream shops - Some locations sell dry ice to the public

Use our dry ice supplier directory to find reliable sources near you.

Conclusion

Shipping with dry ice offers an effective solution for transporting temperature-sensitive items, but requires careful attention to regulations, packaging, and safety considerations. By following the guidelines in this article, you can ensure your shipments arrive safely, comply with all applicable regulations, and maintain the necessary temperature conditions throughout transit.

Remember that requirements may change over time, so always verify current regulations with your chosen carrier before shipping. For regular dry ice shipments, consider developing a relationship with both a reliable dry ice supplier and a shipping carrier representative who can provide ongoing guidance.

For more information about sourcing dry ice for your shipping needs, explore our directory of dry ice suppliers to find reliable providers in your area. And don't forget to review our safety guidelines before handling dry ice for any application.