How Cold Chain Logistics in Cell Therapy Ensure Viability
Your immune cells travel a long journey between collection and infusion, and they need constant care. Cold chain logistics in cell therapy ensure that these living medicines remain viable, safe and personalized. Without the right temperature control, monitoring, and documentation, your cells could lose potency or even pose safety risks. In 2024 only about 20 % of patients eligible for cell or gene therapies could access them because of cost, reimbursement and cold chain logistics challenges. By 2025 the market for cell and gene therapy cold chain services is projected to reach US$2.19 billion, underscoring the need for robust infrastructure. This article—updated November 2025—reveals how cold chain systems keep your therapy safe, what temperature ranges matter, how traceability protects you, and where innovation is heading.
Why cold chain logistics are crucial for cell therapy and how they protect viability and patient safety.
What temperature ranges and cryopreservation methods are used for different therapy types and why ultra low temperatures matter.
How chain of identity and chain of custody ensure traceability and regulatory compliance.
What challenges you face when scaling personalized therapies and how to build a resilient network.
How innovations like AI, digital twins and sustainable packaging are transforming cold chain logistics.
What the latest trends and market insights are for 2025 and how they affect your strategy.
Why Is Cold Chain Logistics Essential for Cell Therapy?
Cold chain logistics are essential because cell therapies are living drugs. These therapies consist of living cells or gene modified cells that are extremely sensitive to temperature changes, contamination and delays. The cold chain provides continuous temperature control, traceability, and coordination across multiple steps—from apheresis (cell collection) to cryogenic storage, manufacturing, shipping, and ultimately reinfusion at the clinic. According to industry guides, rigorous temperature control across packaging, shipping, storage and retrieval protects quality, meets regulatory requirements, and reduces waste. Without a validated cold chain, cells can degrade rapidly, leading to lost viability and patient risk.
The complexity comes from personalization. Cell therapies are tailored to one person, so each shipment is unique. Biocair notes that such therapies may require temperatures as low as −80 °C and rely on real time monitoring, GPS tracking and predictive analytics to ensure the right cells reach the right patient. A single lapse in the chain can jeopardize therapy effectiveness or cause delays that prevent treatment within the narrow infusion window.
Different Stages of the Cell Therapy Journey
Cold chain logistics involve several critical stages:
| Stage | Key Activities | What it means for you |
| Patient collection (apheresis) | Your immune cells are collected at a clinic and labeled with unique identifiers. Proper packaging ensures sterility and temperature control during transport. | Ensures the right cells are collected and shipped quickly to avoid viability loss. |
| Cryogenic storage and cryopreservation | Cells are frozen using controlled rate freezing or vitrification and stored at ultra low temperatures (often below −150 °C) to halt metabolic activity. | Preserves potency and extends shelf life from hours to months or years. |
| Transport to processing facility | Cells are shipped in cryo shippers using liquid nitrogen (LN₂) dry vapor technology that maintains temperatures below −130 °C for days. Advanced monitors track location, temperature and shocks. | Protects your cells from temperature excursions and provides a clear chain of custody. |
| Manufacturing and quality control | Cells are modified or expanded under strict conditions. Traceability ensures that your cells remain linked to you throughout processing. | Guarantees the therapy remains personalized and compliant with privacy regulations. |
| Return shipping and infusion | Finished products are shipped back to the clinic in cryogenic or ultra cold conditions and thawed before infusion. | Ensures the final therapy arrives intact and on schedule so your treatment can proceed. |
Practical tips for protecting your therapy
Train collection staff on proper labeling and packaging. Mislabeling or delayed packing can break the chain of identity.
Use validated LN₂ dry vapor cryo shippers. These devices maintain temperatures below −130 °C and are designed with inner dewars and absorbent walls.
Implement real time monitoring. GPS, temperature and shock sensors provide alerts that allow corrective action before a deviation becomes critical.
Plan for contingencies. Have backup equipment and routes ready to handle flight delays, customs holds or natural disasters. Cryoport notes that building scalability into the supply chain is essential to ensure patient outcomes.
Real world example: A clinical trial used dry vapor cryo shippers with LN₂ to transport CAR T cells across continents. With continuous temperature and geolocation monitoring, the shipment maintained below −130 °C for 10 days, allowing safe infusion even after unexpected customs delays.
What Temperature Ranges and Cryopreservation Methods Are Used?
Different therapies require distinct temperature ranges, and matching them is critical for product integrity. Cell and gene therapy materials are extremely sensitive to heat and must be stored at ultra low or cryogenic temperatures. A widely used classification includes:
Cryogenic (< −150 °C). Cell therapies like CAR T and gene modified cells must remain below −130 °C (often in the −150 °C to −196 °C range) to halt metabolism and preserve viability.
Ultra low (−70 °C to −80 °C). Viral vectors such as adeno associated viruses (AAV) are stable around −80 °C.
Refrigerated (2 °C to 8 °C). Many biologics and some gene therapies can be stored in refrigerated conditions for short periods.
Controlled room temperature (20 °C to 25 °C). Certain reagents or ancillary materials may be transported at room temperature.
Cryopreservation methods matter. Controlled rate freezing gradually lowers the temperature to minimize ice crystal formation, while vitrification (a rapid cooling method) avoids crystallization altogether. After freezing, samples are stored in LN₂ at −135 °C to −196 °C. SciSafe notes that cryopreservation extends shelf life: fresh cell therapies may have only a 12–96 hour shelf life, whereas cryopreserved products can be stored long term. Without proper cryopreservation, cells quickly lose viability or functionality.
Choosing the Right Cryo shipper and Monitoring Tools
Cryo shippers are the workhorses of cell therapy logistics. A typical cryo shipper uses LN₂ dry vapor that maintains temperatures below −130 °C without free liquid nitrogen, preventing spills and pressure hazards. The design includes an inner dewar lined with absorbent materials; as liquid nitrogen evaporates, the dry vapor fills the chamber and keeps contents cold. These devices can maintain cryogenic temperatures for several days or weeks.
Cryoport, a leading provider, offers cryogenic shipping systems that maintain −150 °C or lower for up to 10 days, with integrated real time monitoring and a proprietary decontamination process. The monitoring system tracks geolocation, temperature, shock and tilt, and it can alert operators if a parameter drifts. This ensures you and your healthcare team can intervene quickly.
| Temperature range | Typical products | Cryopreservation method | What it means for you |
| < −150 °C (cryogenic) | CAR T cells, gene modified T cells, stem cells | Controlled rate freezing, vitrification, stored in LN₂ | Maintains cell potency for months to years; requires specialized cryo shippers. |
| −70 °C to −80 °C (ultra low) | Viral vectors, AAV gene therapies | Freezer storage with dry ice or mechanical freezers | Suitable for short to medium term; easier to handle but still requires temperature monitors. |
| 2 °C to 8 °C (refrigerated) | Antibodies, some gene therapies | Refrigerators; may include cryoprotectants | Used for ancillary materials or final products during short transit. |
| 20 °C to 25 °C (controlled room) | Enzymes, buffers, collection kits | Room temperature packaging | Only certain materials; still need chain of custody documentation. |
Practical tips for temperature management
Select cryo shippers validated for your temperature range. For CAR T products needing < −135 °C, choose LN₂ dry vapor systems; for −80 °C viral vectors, ensure extended dry ice supply.
Use controlled rate freezers and qualified personnel. Rapid uncontrolled freezing can damage cells; training ensures uniform freezing and thawing.
Integrate remote monitoring. Devices like Smartpak provide real time data on temperature, location and shock.
Consider storage redundancy. CAR T cell second doses must remain below −135 °C; even brief temperature excursions can impair efficacy. Backup freezers and generators mitigate risk.
Real world example: A manufacturing site kept a second dose of CAR T cells in a cryogenic freezer at −150 °C while the first dose was administered. When the patient relapsed months later, the second dose maintained full potency thanks to continuous temperature monitoring and dual redundant freezers.
How Do Supply Chain Links and Traceability Protect Patients?
Traceability protects patients by ensuring their cells remain uniquely identified and properly handled at every step. Two related concepts drive this protection:
Chain of custody (COC) is the permanent record of who handled the product, what actions were performed, and when and where those actions occurred. It ensures accountability and allows investigators to reconstruct the journey.
Chain of identity (COI) is the permanent association between the patient’s tissue or cells and the resulting product, maintained through unique identifiers and documentation. It prevents mix ups between donors and recipients.
Combining COC and COI is unique to cell and gene therapies. Each organization must maintain a gapless audit trail and manage personally identifiable data to comply with privacy laws such as GDPR and HIPAA. When done properly, traceability allows clinicians to confirm that the therapy they administer belongs to the right patient and that it maintained quality standards throughout the journey.
Ensuring Compliance and Data Integrity
Cold chain logistics must also satisfy regulatory requirements such as Good Distribution Practices (GDP), Good Manufacturing Practices (GMP) and regional guidelines. Beyond standard pharmaceutical distribution, cell therapies require:
Precise documentation and labeling. Each sample must carry a unique identifier that ties back to the patient record and manufacturing batch. Mislabeling risks cross administration.
Continuous data capture. Temperature, location and handling data must be logged in real time using IoT sensors. The information should be immutable to create a clear audit trail.
Secure data management. Because patient data are sensitive, logistics providers must implement encryption, access controls and compliance with privacy regulations.
Cross organizational collaboration. From collection centers to transport providers, manufacturers and clinics, every handoff must preserve COI and COC.
| Traceability element | Description | Importance to you |
| Chain of custody | Records who handled your sample, when and where, along with actions performed | Enables investigation of any deviation and ensures accountability across organizations. |
| Chain of identity | Links your cells to the final therapy through unique identifiers and documentation | Prevents mix ups; guarantees the therapy you receive is truly yours. |
| Chain of compliance | Aligns practices with regulations (FDA, EMA, GDP) and quality standards | Ensures your therapy meets safety and efficacy standards and can be legally administered. |
Practical tips for traceability
Implement digital track and trace systems. Blockchain or secure databases can capture immutable records.
Audit your partners. Assess the ability of transport providers, manufacturers and clinics to maintain COC/COI and comply with data privacy rules.
Standardize labeling and documentation. Use barcodes or RFID tags to automate scanning and reduce human error.
Educate clinicians and coordinators. Everyone who touches the sample must understand traceability requirements and follow proper procedures.
Real world example: In one commercial CAR T program, a digital chain of identity platform used QR codes and mobile scanning across collection, processing and infusion sites. When regulators audited the process, the system produced a seamless audit trail demonstrating compliance and preventing potential cross administrations.
What Are the Challenges and Solutions in Scaling Cold Chain for Personalized Therapies?
Scaling the cold chain for personalized therapies is challenging because the infrastructure, workforce and regulatory systems were designed for mass produced pharmaceuticals, not one patient batches. Several specific hurdles arise:
Limited infrastructure and scalability. Many clinics and manufacturing facilities lack sufficient cryogenic freezers, backup generators or validated shipping lanes. Access to cell and gene therapies has reached only about 20 % of eligible patients due to cost, reimbursement and cold chain limitations.
Short shelf life of fresh products. Fresh cell or gene therapy products often have a shelf life of just 12–96 hours, requiring rapid transport and scheduling.
Regulatory complexity. Each country has its own GMP/GDP requirements, customs procedures and labeling standards.
Workforce shortages. Handling cryogenic shipments requires trained personnel; there is a shortage of skilled workers in logistics and manufacturing.
Cost and reimbursement. The high cost of therapies and logistics may not be fully covered by payers, limiting patient access.
Building a Resilient and Flexible Network
To overcome these obstacles, companies and healthcare systems are adopting several strategies:
Design for scalability early. Plan end to end supply chain integration from clinical trials through commercialization. Cryoport’s platform supports early phase consulting, standardized apheresis kits, lane qualification and integrated shipping systems to reduce risk.
Invest in infrastructure. Upgrading freezers, warehousing and backup power ensures capacity for cryogenic storage and prevents temperature excursions.
Collaborate with specialized carriers. Partnerships with carriers experienced in cryogenic and ultra low transport ensure proper handling and documentation.
Perform lane qualification and risk assessment. Validate shipping routes under simulated and real conditions to confirm that cryogenic conditions hold and that contingencies are in place.
Standardize training and processes. Cross train staff across collection sites, shipping providers and clinics to reduce errors and build redundancy.
| Challenge | Impact | Solution | How it helps you |
| Limited capacity | Delays in therapy availability and potential viability loss | Build or partner with cryogenic storage facilities; use reusable cryo shipper fleets | Ensures timely delivery and reduces risk of product spoilage. |
| Shelf life constraints | Necessitates rapid scheduling and shipping | Use cryopreservation to extend storage and plan manufacturing slots carefully | Provides flexibility in treatment scheduling and reduces wasted doses. |
| Regulatory differences | Compliance issues at borders | Employ regional experts and pre clear shipments; maintain comprehensive documentation | Prevents customs delays and ensures your therapy crosses borders smoothly. |
| Workforce shortage | Increased risk of mishandling | Develop training programs and automation to reduce manual steps | Improves handling consistency and reduces errors. |
Practical tips for scaling
Start supply chain planning at the clinical phase. Avoid retrofitting logistics after approval; design your network with commercialization in mind.
Use reusable packaging and optimize routes. Reusable LN₂ vessels and route optimization lower costs and environmental impact.
Create contingency plans. Identify alternate carriers, airports and storage sites to keep your therapy moving during disruptions.
Engage with payers early. Clarify reimbursement for logistics services to reduce financial barriers.
Real world example: A therapy developer worked with a logistics provider to pre qualify shipping lanes across North America and Europe. They simulated worst case scenarios, such as flight cancellations and customs holds. After commercialization, the therapy achieved 98 % on time delivery and reduced lost doses by 50 % compared with early trials.
How Are Innovations and AI Transforming Cold Chain Logistics?
Digital technologies and AI are revolutionizing cold chain logistics by enhancing visibility, predicting risks and reducing costs. The TowardsHealthcare report highlights that AI helps monitor temperatures in real time, detect deviations, manage pickup and inventory scheduling, analyze weather conditions and optimize routes—ultimately improving quality and risk management while lowering failure rates.
Key innovation areas include:
IoT sensors and remote monitoring. Smart sensors embedded in cryo shippers record temperature, humidity, vibration and geolocation. Real time data allow rapid intervention if a shipment deviates from its temperature range.
AI and machine learning. Algorithms analyze historic and real time data to predict delays (weather, traffic, customs), optimize routing and schedule pickups to match manufacturing slots.
Digital twins. Virtual models of physical logistics systems can simulate transport conditions, test packaging designs and assess potential risks without exposing actual products.
Blockchain and secure data exchange. Distributed ledgers can store immutable records of chain of custody events, strengthening traceability and compliance.
Sustainable packaging. Reusable cryo shippers, phase change materials and vacuum insulation panels reduce waste and carbon footprint. Some new materials enable longer duration at ultra low temperatures with less energy.
AI Driven Tools and Digital Twins
Predictive analytics. AI models predict equipment failure and schedule maintenance, reducing unexpected downtime.
Dynamic route optimization. Real time data are used to reroute shipments around weather events or geopolitical disruptions.
Capacity planning. Digital twins help model demand scenarios and allocate cryogenic storage, shipping assets and staffing accordingly.
Autonomous documentation. Optical character recognition (OCR) and natural language processing (NLP) automate data capture from shipping documents, reducing manual entry.
| Innovation | Description | Benefit for you |
| IoT sensors | Temperature, location and shock sensors embedded in packaging | Provides real time visibility and allows corrective actions before product loss. |
| AI algorithms | Machine learning models predict delays and optimize routes | Reduces risk of missed infusion windows and lowers costs. |
| Digital twins | Virtual replicas of logistics systems used for simulation | Helps you test new packaging or routes without risking real products. |
| Blockchain | Distributed ledger storing immutable data | Strengthens chain of identity and prevents data tampering. |
| Sustainable materials | Reusable cryo shippers and insulated containers | Lowers environmental impact and operating costs. |
Practical tips for adopting innovation
Pilot AI tools on a small scale. Test route optimization or predictive maintenance on select shipments before scaling.
Integrate data systems. Connect collection sites, manufacturing and logistics providers via a shared platform to enable real time data exchange.
Assess cybersecurity. Protect sensitive patient data by implementing encryption, access control and regular audits.
Track sustainability metrics. Monitor carbon footprint, packaging reuse and energy consumption to improve environmental performance.
Real world example: A logistics provider implemented AI driven scheduling that considered weather forecasts, flight schedules and manufacturing slot availability. By rerouting shipments around storms and optimizing pickup times, they reduced temperature excursions by 20 % and saved 15 % in shipping costs.
2025 Latest Developments and Trends in Cold Chain Logistics for Cell Therapy
Trend overview
By November 2025, cold chain logistics have become a strategic focus for both biotech and logistics companies. Demand for advanced therapies keeps growing; more biologics were in development in 2024 than any medicine type in 1996, and 14 of the top 20 best selling drugs require storage at 2–8 °C. Infrastructure, however, lags behind innovation, leading to access barriers. The cell and gene therapy cold chain market is expected to grow from US$1.89 billion in 2024 to US$8.06 billion by 2034 with a compound annual growth rate (CAGR) of 15.64 %. North America currently accounts for 44 % of the market, the cryogenic segment holds 52 %, and transportation makes up 48 %.
General cold chain logistics (including food, vaccines and pharmaceuticals) is also booming; the global market was US$293.58 billion in 2023 and is projected to reach US$862.33 billion by 2032, a CAGR of 13 %. Maersk reports that businesses are investing in stronger visibility through software, upgrading aging storage facilities, navigating geopolitical influences and launching more products requiring cold chain. These trends signal continued investment and partnerships to build integrated, resilient supply chains.
Latest advances at a glance
Stronger visibility platforms: Companies deploy integrated software that consolidates data from sensors, shipping manifests and manufacturing schedules, enabling end to end visibility and faster interventions.
Upgraded storage facilities: Aging warehouses are being replaced or retrofitted with energy efficient freezers, backup power and sustainable cooling systems to meet environmental regulations.
Geopolitical awareness: Logistics plans now include contingency routes to circumvent geopolitical disruptions, port closures or trade disputes.
New products entering the pipeline: Besides cell therapies, more mRNA vaccines, biologics and individualized treatments require cold chain infrastructure, increasing competition for capacity.
Expanded distribution hubs: Larger regional hubs near clinical sites reduce transit times and allow decoupling of manufacturing location from patient location.
Market insights
Regional variations: North America’s dominance reflects early adoption of gene and cell therapies. Europe and Asia Pacific are investing heavily in infrastructure and regulatory frameworks.
Segment performance: Cryogenic storage is the largest segment due to cell therapy requirements. The transportation segment is also significant, highlighting the importance of specialized carriers.
Technological adoption: AI, IoT and digital platforms are becoming standard; providers that fail to adopt may struggle to meet regulatory and customer expectations.
Sustainability pressure: Companies face pressure from regulators and customers to reduce packaging waste and carbon emissions, leading to adoption of reusable cryo shippers and energy efficient facilities.
Frequently Asked Questions
- How long can cell therapies stay viable during shipping?Cryo shippers using LN₂ dry vapor can maintain cryogenic temperatures below −130 °C for several days or even weeks. This allows enough time for international transport and customs clearance. For fresh products not cryopreserved, the shelf life may be 12–96 hours, so timing is critical.
- What is the difference between chain of custody and chain of identity?Chain of custody records who handles the sample, what actions are taken and when. Chain of identity permanently links your cells to the final therapy using unique identifiers. Together they ensure traceability and prevent mix ups.
- Why are cryogenic temperatures necessary for CAR T products?CAR T cells are living immune cells that can quickly lose function if metabolic activity resumes. Storing them below −130 °C or even below −150 °C halts metabolism and preserves potency. Without cryogenic storage, viability declines and the therapy may be ineffective.
- How do AI and IoT improve cold chain logistics?AI analyzes real time and historical data to predict delays, optimize routes and schedule pickups, reducing temperature excursions and costs. IoT sensors provide continuous data on temperature, location and shocks, enabling rapid intervention before product loss.
- What should I look for in a logistics partner?Choose providers with validated cryo shipping systems, real time monitoring, documented chain of identity and custody processes, and experience with regulatory compliance. Look for partners who invest in digital platforms and sustainability initiatives.
Summary and Recommendations
In the rapidly evolving field of cell therapy, cold chain logistics in cell therapy play a decisive role in product quality, patient safety and access. Key takeaways from this guide include:
Temperature control is non negotiable. Cell therapies require cryogenic or ultra low storage to remain viable. Choose the right cryo shipper and cryopreservation method.
Traceability protects patients. Maintaining chain of custody and chain of identity is crucial. Digital systems and standardized labeling are essential.
Scaling personalized therapies requires planning. Start supply chain design early, perform lane qualification, and train staff. Infrastructure investments and partnerships will reduce delays.
Innovations such as AI and IoT enhance resilience. These technologies deliver real time visibility, predictive analytics and sustainable packaging.
Trends point to growth and transformation. The market is expanding rapidly; staying ahead requires continuous improvement and adaptation.
Actionable next steps
Assess your current supply chain. Use a readiness checklist or interactive tool to identify gaps in temperature control, traceability and capacity. Document existing procedures and training needs.
Engage with experienced partners. Whether you are a therapy developer or a healthcare provider, collaborate with specialized logistics providers who offer validated cryogenic systems and integrated monitoring.
Invest in digital platforms. Implement end to end data systems for tracking, predictive analytics and secure data exchange. Train teams on their use.
Plan for scalability and sustainability. Consider reusable packaging, backup equipment, and contingency routes. Monitor carbon footprint and work toward environmental targets.
Stay informed about evolving regulations and technologies. Attend industry forums, read guidelines and adapt your processes accordingly.
About Tempk
At Tempk, we specialize in advanced cold chain solutions tailored for cell and gene therapies. Our portfolio includes LN₂ dry vapor cryo shippers, controlled rate freezers, and real time monitoring systems. We combine decades of cold chain expertise with cutting edge technology to provide end to end support—from clinical trial logistics to commercial-scale distribution. Our integrated platforms maintain chain of custody and identity, ensuring patient safety and regulatory compliance. We continually invest in sustainable packaging and digital innovations to deliver reliable, environmentally responsible solutions.
Ready to safeguard your therapy? Contact us for a consultation and discover how our logistics experts can support your cell therapy program at every stage.
