ColdPackROI Studio — Free Interactive In-Browser Studio
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Quick Reference & Frequently Asked Questions
How much dry ice vs. gel packs do I need for a 48-hour perishable shipment?
Dry ice sublimates (turns directly from solid to gas) at 5 to 10 pounds per 24 hours depending on your insulated liner's R-value. For a 48-hour frozen shipment in a 1.5-inch EPS or ClimaCell cooler, you need 10 to 14 lbs of dry ice. For refrigerated (34°F–42°F) chocolate, cheese, or meal kits, use a 1:3 ratio of phase-change gel packs to product weight.
Why does 1.5-inch insulated foam inflate carrier dimensional weight (DIM) so severely?
Adding 1.5-inch insulated walls to all 6 sides of an 8×8×8 inch inner payload cavity expands the outer shipping carton to 11×11×11 inches (1,331 cubic inches). Under the 139 carrier DIM divisor, your billable DIM weight jumps from 4 lbs to 10 lbs before adding a single ounce of gel pack.
When is 2-Day Air actually cheaper than 3-Day Ground for cold-chain DTC?
In summer zones (Zones 5–7), 3-Day Ground requires a thicker cooler (+$3.50), an extra 4 lbs of gel packs (+$2.60 + $4.20 weight surcharge), and still suffers a 6%–9% warm-arrival reship rate (+$5.50 expected loss). Upgrading to 2-Day Air in a slim insulated mailer often saves $2.00 to $4.50 per box net.
What carrier surcharges apply when shipping dry ice via UPS or FedEx?
Dry ice is regulated as a Class 9 hazardous material (UN1845) for air transport. Both UPS and FedEx charge a $6.00 to $7.50 Dry Ice handling surcharge on air parcels and require vented outer cartons marked with net dry ice weight in kilograms.