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Cold Chain Technologies Redesigns Biopharma Shipping System to Cut Dry Ice Dependence

Cold Chain Technologies has completed a redesign of a global biopharma customer’s temperature-controlled shipping system, replacing a legacy dry-ice and EPS solution with a data-led packaging strategy.

The project began with an analysis of actual shipment patterns. More than half of the customer’s orders contained three cartons or fewer, indicating that its existing packaging was often larger than necessary. By creating a more targeted range of shipment sizes, the new design reduces empty space, material use and freight inefficiency.

The replacement system combines paper-based thermal packaging with a water-based refrigerant carton. The aim is to maintain the required thermal protection while reducing dependence on dry ice, which can add safety, handling and regulatory complexity across warehousing and fulfilment operations.

Lifecycle assessment work showed that the paper-based option delivered the lowest environmental impact among the evaluated insulation choices, while the water-based refrigerant performed more favourably than dry ice from a sustainability perspective. The redesigned packaging also gives recipients a simpler disposal process, helping improve the end-user experience.

The project reflects a broader shift in pharmaceutical cold-chain logistics: packaging is increasingly being designed around real shipment profiles, thermal performance and end-of-life management—not only around temperature duration.