A tightening supply of carbon dioxide is limiting dry ice availability, driving increased adoption of alternative temperature-control methods across cold-chain logistics. Since late 2025, food, pharmaceutical, and biotech sectors have shifted strategies in response to energy price volatility and regional CO₂ production constraints, amid projections of more severe supply stress in 2026 unless capacity expands.1Cold-chain packaging companies adapt as dry ice supply falters | Packaging Dive
Background
Dry ice, valued for its high cooling capacity, sublimation, and cost-effectiveness, has long been central to ultra-cold shipments. However, CO₂ production has grown by only 0.3% annually over the past decade, while dry ice demand has risen by approximately 5% per year. In the U.S., plant closures in California are forecast to reduce CO₂ output by nearly 850 tons per day by early 2026, raising concerns over supply continuity.1Cold-chain packaging companies adapt as dry ice supply falters | Packaging Dive
Pharmaceutical and food sectors face increasing pressure to maintain cold-chain integrity amid evolving regulatory and sustainability requirements. In Europe and North America, packaging waste directives and stricter temperature tracking standards are prompting the shift toward more traceable, reusable, and lower-emission solutions.2Temperature Control Packaging Market - PW Consulting Chemical & Energy Research Center
Details
Several alternative cooling strategies are gaining momentum. Phase-change materials (PCMs) provide consistent temperature control and can extend hold times beyond 72 hours, while also lowering CO₂ emissions-water-based PCMs reduce emissions by about 39%.3Cold Chain Insulation: Sustainable Materials & Trends for 2025 - tempk Vacuum-insulated panels (VIPs) and aerogel composites improve insulation efficiency with ultra-low thermal conductivity, decreasing package weight and transport emissions, albeit with higher initial costs.3Cold Chain Insulation: Sustainable Materials & Trends for 2025 - tempk In Germany, Va-Q-tec has introduced a reusable PCM panel (-67 °C eutectic salt hydrate) that replaces dry ice for cell and gene therapy shipments.4Phase Change Matters newsletter | November 2023 - pcm-ral
Hybrid systems combining active refrigeration and passive insulation are also emerging. Battery-powered, reusable coolers-such as Artyc's Medstow 5L-use onboard compressors, real-time monitoring, and GPS tracking to maintain temperatures without dry ice.5The Future of Cold Chain: Innovations and Trends in Logistics Some providers are redesigning insulated containers with advanced insulation and optimized geometry to maximize dry ice efficiency.1Cold-chain packaging companies adapt as dry ice supply falters | Packaging Dive Mixing cooling media is increasingly common; salt- or gel-based alternatives, while costlier per unit, offer supply resilience and regulatory benefits.1Cold-chain packaging companies adapt as dry ice supply falters | Packaging Dive New sustainable materials such as cellulose-based insulators and curbside-recyclable packaging are undergoing testing to meet environmental directives and reduce dependence on EPS and single-use plastics.1Cold-chain packaging companies adapt as dry ice supply falters | Packaging Dive
Outlook
Cold-chain operators are expected to continue diversifying temperature-control strategies over the next 12 to 24 months, weighing capital investments against long-term resilience, cost stability, and sustainability gains. With CO₂ constraints likely to persist, hybrid systems, reusable shippers, advanced PCMs, and enhanced insulation are set to influence logistics planning, traceability, and capital allocation throughout cold-chain networks.
