Cold chain packaging manufacturers: who leads the field in 2025?
Updated: November 16, 2025
In 2025 the global cold chain packaging market is booming. Growing demand for pharmaceuticals, biologics, vaccines, fresh foods and other temperature sensitive products has lifted the market value to around US $27.7 billion and analysts expect it to reach US $102.1 billion by 2034. To protect delicate goods, cold chain packaging manufacturers have adopted smart sensors, sustainable materials and reusable designs, and they must comply with strict regulatory standards. If you’re wondering which manufacturers lead the field, what innovations they offer and how to choose the right partner, this comprehensive guide demystifies the market.
Definition and basics: what cold chain packaging is and why it matters, with insights on vacuum sealed (Cryovac) packaging and reusable temperature controlled systems.
Key manufacturers: profiles of Sonoco ThermoSafe, Peli BioThermal, Cold Chain Technologies, Sealed Air (Cryovac), va Q tec and Softbox/CSafe with notable products and sustainability pledges.
Market insights: analysis of product categories, applications and regional trends, plus market drivers and constraints.
2025 trends: how AI, IoT, automation, sustainability and stricter regulations are shaping packaging designs.
FAQs: answers to common questions about shelf life, compliance and choosing suppliers.
What is cold chain packaging and why is it critical?
Cold chain packaging refers to insulated containers, phase change materials and monitoring devices designed to keep products within strict temperature ranges during storage and transportation. This packaging ensures that pharmaceuticals, biologics, vaccines, fresh foods and other temperature sensitive goods remain potent and safe. Without proper packaging, temperature excursions can degrade vaccines or spoil food, leading to waste and health risks. Modern cold chain packaging includes single use boxes, reusable pallet shippers, temperature logging devices and smart labels.
Vacuum sealed (Cryovac) packaging: preserving freshness
Cryovac packaging is a vacuum sealing technique often used for meats and dairy products. The process involves placing the product in a high barrier, airtight bag, removing the air and heat sealing the bag. This method eliminates oxygen, prevents spoilage and dramatically extends shelf life. An additional benefit is reduced plastic use; Cryovac packages create a tight skin around the product, cutting down on material consumption and minimizing waste. Unlike simple vacuum bags, Cryovac uses specialized materials and machinery to provide improved product protection, leak resistance and durability, making it popular for high value cuts and export shipments.
Tip: If you regularly ship fresh or frozen proteins, consider suppliers that offer Cryovac or vacuum packaging options; they can extend shelf life and reduce waste.
Reusable temperature controlled packaging
Reusable cold chain packaging systems use durable insulated containers and replaceable refrigerants to maintain temperatures over multiple trips. This approach lowers total cost of ownership and reduces environmental impact. According to a 2025 market report, the reusable temperature controlled packaging market reached US $2.5 billion in 2024 and is expected to double by 2033. Reusable designs support sustainability goals by minimizing single use waste and often integrate digital tracking to ensure safe returns. When evaluating suppliers, check whether they offer return logistics and refurbishment services.
How is the cold chain packaging market structured?
Product categories and market share
Analysts segment the cold chain packaging market into insulated containers, pallet shippers, refrigerants (phase change materials and gel packs) and monitoring devices. Insulated containers (boxes, tubs and pouches) account for about 40 % of the market, while pallet shippers hold around 25 %. Phase change materials and smart monitoring devices provide precise temperature control and real time visibility. With increasing emphasis on sustainability, reusable systems and natural refrigerants such as water based gels are gaining traction.
Application sectors
Pharmaceuticals and biologics dominate the cold chain packaging market, representing 55 % of demand, while food and beverages account for roughly 35 %. Growth in gene and cell therapies, mRNA vaccines, specialty pharmacy and direct to patient deliveries increases demand for ultra cold (-80 °C to -150 °C) and cryogenic packaging solutions. Fresh produce, seafood and dairy require moderate cold (0 °C to 8 °C), while frozen foods need deep frozen (-20 °C) capabilities.
Regional outlook
The market is global but concentrated in North America, Europe and Asia. North America leads due to strong pharmaceutical production and e grocery services, while Asia Pacific is the fastest growing region driven by expanding cold storage infrastructure. According to TowardsPackaging, the market was US $34.28 billion in 2024 and will climb to nearly US $90 billion by 2034 (CAGR ≈ 11 %).
How to choose a cold chain packaging manufacturer
Picking the right partner involves balancing technical performance, sustainability, cost and service. Consider the following criteria:
Temperature performance & hold time: Does the solution meet your required temperature range and duration (e.g., 2–8 °C for 96 hours)?
Regulatory compliance: Are products tested to standards like ISTA 7D and compliant with GDP and IATA requirements? Reputable manufacturers will provide qualification data.
Reusable vs. single use: Reusable systems offer lower long term cost and environmental benefits; single use boxes may suit small or one off shipments.
Sustainability: Check whether materials are recyclable or biodegradable and whether manufacturers have sustainability pledges.
Digital monitoring: Modern solutions integrate IoT sensors, data loggers and platforms for real time visibility and predictive analytics.
Global support & logistics: Choose partners with global service networks to ensure packaging availability and return logistics.
Profiles of leading cold chain packaging manufacturers
Below we spotlight major manufacturers and highlight their flagship products, sustainability initiatives and key differentiators.
Sonoco ThermoSafe
Overview. ThermoSafe (now being sold by Sonoco to Arsenal Capital Partners for up to US $725 million as announced in September 2025) has long been a global leader in temperature controlled packaging. The company specializes in insulated shippers, gel packs, phase change materials, dry ice containers and custom engineering services for pharmaceuticals, biologics and vaccines. ThermoSafe generated over US $240 million in sales in 2024.
Innovations and services.
Comprehensive product range: From cold shipping boxes and gel packs to foam bricks and durable insulated containers, ThermoSafe offers solutions for parcel and pallet shipments.
Engineering and testing: The company provides custom design, thermal testing and consulting to tailor packaging to client needs.
Global network: With a worldwide presence, ThermoSafe can support cross border shipments and return logistics.
Recent developments. In 2025 Sonoco agreed to sell ThermoSafe to Arsenal Capital Partners, signaling a strategic pivot for Sonoco while maintaining ThermoSafe’s focus on advanced cold chain solutions.
Peli BioThermal
Overview. Peli BioThermal designs reusable temperature controlled shippers such as the Crēdo™ Cube and Crēdo™ GO and offers rental programs. The company emphasizes sustainability and reduced dry ice usage.
Crēdo Cube™ Dry Ice shipper. This reusable parcel shipper maintains ultra cold conditions (down to -20 °C or lower) for over 144 hours; some modules achieve up to 240 hours of hold time. It reduces dry ice consumption by 75 %, supporting companies’ ESG goals, while providing precision and reliability. Peli BioThermal positions the Crēdo Cube as a safer alternative to single use EPS boxes for deep frozen biologics and gene therapies.
Industry collaborations. Peli BioThermal works with logistics partners like Biocair to deliver global solutions. Thought leadership articles emphasize the importance of validated packaging, global availability and collaboration to maintain strict temperature ranges and regulatory compliance. Peli BioThermal and Biocair are jointly developing reusable systems to reduce environmental impact and maintain product integrity during extended transit.
Cold Chain Technologies (CCT)
Overview. CCT is a provider of insulated packaging and digital monitoring solutions for life sciences. Its offerings include reusable shippers, single use sustainable boxes, thermal covers and digital services. CCT ships more than 12.5 million reusable shippers each year, avoiding over 102 million pounds of landfill waste and has distributed over 500 million COVID 19 vaccine doses.
Smart Solutions platform. CCT’s Smart Solutions platform uses AI and IoT to plan, execute and monitor shipments. The platform recommends packaging solutions based on duration, required temperature range, shipper type and weather; consolidates ordering for gel packs, phase change materials and reusable shippers; and integrates real time tracking via cellular loggers and geofencing. Predictive analytics provide insights to prevent thermal excursions.
Acquisition of Tower Cold Chain. In January 2025 CCT announced the acquisition of Tower Cold Chain, a passive reusable packaging specialist, expanding its product portfolio and global footprint.
Sealed Air (Cryovac® brand)
Overview. Sealed Air pioneered the Cryovac® vacuum sealed packaging process and is known for high barrier films and shrink bags used to extend shelf life of meats and dairy. The company has pledged that all packaging solutions will be 100 % recyclable or reusable by 2025 and plans to achieve 50 % average recycled content (60 % post consumer).
Sustainability initiatives. Sealed Air invests in plant based materials like Plantic™ starch films and EcoPure™ foams, and works with partners to develop curbside recyclable temperature assurance solutions. Through its membership in the Ellen MacArthur Foundation’s New Plastics Economy, Sealed Air advocates for circular packaging systems.
Cryovac packaging benefits. Cryovac packaging uses specialized high barrier bags and controlled heat sealing to extend shelf life and provide leak resistant, durable protection. While Cryovac systems are more expensive than basic vacuum sealing, they offer improved product safety and quality, making them a preferred choice for exporters.
va Q tec
Overview. German company va Q tec is a technology leader in vacuum insulation panels (VIPs), phase change materials (PCMs) and thermal packaging systems. Its solutions combine high performance insulation with sustainable materials and reusable designs.
Vacuum insulation panels. va Q tec’s VIPs provide up to ten times better insulation than conventional materials and deliver up to 90 % better performance. They enable energy efficient packaging with minimal thickness, making them ideal for high value pharmaceuticals, electronics and perishable foods. Product advantages include decades long durability, customized shapes and coatings, patented va Q check® quality testing for each panel, and climate neutral production in Germany.
Phase change materials. The company has developed customized PCMs for over 15 years. PCMs act as latent heat storage elements, stabilizing temperatures in transport boxes and battery cases. va Q tec’s compact PCM formats (hard or soft shells) can be used directly in transport boxes or containers to maintain constant temperatures. They are widely used for pharmaceuticals, sensitive food and battery management applications.
Thermal packaging systems. Combining VIPs and PCMs, va Q tec’s systems offer high performance insulation with reusable designs and digital monitoring. They emphasize quality, reliability and sustainability. The company also provides tools like U value calculators and Kelvin Hours calculators to help customers model thermal performance.
Softbox/CSafe
Overview. Softbox, now part of CSafe Global, specializes in passive temperature controlled packaging for the pharmaceutical and life science industries. Its solutions integrate vacuum insulated panels, phase change materials and real time tracking.
Softbox VIP and VIP+. The Softbox VIP parcel solution uses best in class VIP insulation and is available in single use or multi use configurations. It is designed for payload sizes from 5 L to 56 L and provides hold times of 96 to 240 hours depending on configuration. Temperature ranges include -25 °C to -15 °C, +2 °C to +8 °C, +15 °C to +25 °C and below −60 °C (dry ice). The VIP+ version adds enhanced reusability and an integrated data logger for real time shipment visibility. Features include reusable carton design, integrated handles, simplified pack out, ISTA 7D qualification, and a reuse and requalification program.
Other innovations. Earlier Softbox products like Tempcell ECO, Tempcell MAX and Silverpod MAX demonstrate the company’s innovation in recyclable materials and PCM technology. Tempcell ECO uses corrugated paper and is 100 % kerbside recyclable. Tempcell MAX offers 96 hours of thermal protection using a SilverSkin™ radiant barrier and recyclable PCM coolants. Silverpod MAX is a high performance pallet shipper with PCM coolants and a reflective barrier for enhanced thermal performance. Softbox also introduced AEON Metro, a reusable multi drop delivery shipper that provides up to 48 hours of protection and reduces the need for temperature controlled vehicles.
Comparative summary
| Manufacturer | Flagship products | Key advantages | What it means for you |
| Sonoco ThermoSafe | Cold shipping boxes, gel packs, foam bricks; custom engineering services | Comprehensive portfolio; global network; engineering expertise | Reliable partner for a wide range of temperature ranges and shipment sizes; engineering support simplifies custom needs |
| Peli BioThermal | Crēdo Cube™ reusable shippers; Crēdo GO; rental programs | Ultra cold performance (144–240 h hold time); reduces dry ice usage by 75 %; sustainability focus | Ideal for gene therapy and biologics requiring deep frozen shipments; rental program lowers capital investment |
| Cold Chain Technologies (CCT) | Smart Solutions digital platform; reusable pallet and parcel shippers; thermal covers | AI driven planning, IoT tracking, predictive analytics; 12.5 million reusable shippers/year | Provides end to end visibility and optimization; reduces waste and improves compliance |
| Sealed Air (Cryovac) | Cryovac® vacuum sealed bags and shrink films; plant based and recyclable materials | Extends shelf life; high barrier properties; pledge for 100 % recyclable/reusable packaging by 2025 | Suitable for meats and dairy; sustainable packaging helps meet corporate ESG goals |
| va Q tec | Vacuum insulation panels (VIPs); phase change materials (PCMs); thermal packaging systems | Up to ten times better insulation; custom shapes; climate neutral production | Best for high value pharma or electronics requiring compact, high performance insulation; sustainable design reduces energy use |
| Softbox/CSafe | Softbox VIP and VIP+ shippers; Tempcell ECO/MAX; Silverpod MAX; AEON Metro | Long hold times (96–240 h); VIP insulation; integrated data loggers; recyclable materials | Offers flexible parcel and pallet solutions, from ultra cold to ambient; reusability and real time tracking enhance control |
Practical tips and recommendations
Match hold time to transit time. Ensure the shipper’s thermal duration (e.g., 96 or 240 hours) covers the entire journey including potential delays.
Use digital monitoring. Select packaging with integrated data loggers or IoT sensors; real time alerts help prevent temperature excursions.
Prioritize sustainability. Choose reusable systems, recyclable materials and manufacturers with clear sustainability commitments.
Plan return logistics. For reusable shippers, coordinate collection and refurbishment to maximize environmental benefits.
Case example: A U.S. biotech company shipping mRNA vaccines to Southeast Asia used Peli BioThermal’s Crēdo Cube™ Dry Ice and integrated data loggers. The 240 hour hold time and 75 % reduction in dry ice consumption allowed them to maintain -80 °C conditions for five days and significantly cut CO₂ emissions. By coupling the shipper with digital tracking from CCT, the firm achieved zero temperature excursions and simplified customs clearance.
Emerging trends in 2025
AI, automation and robotics
The cold chain industry is embracing AI powered route optimization, predictive analytics and robotic handling to counter labor shortages and improve efficiency. Automation enhances warehouse throughput and reduces human errors, while AI forecasts delays and suggests alternative routes. These technologies also enable dynamic planning for packaging selection and refrigerant quantities.
Real time tracking and visibility
End to end visibility has become a standard requirement. IoT sensors embedded in packages transmit temperature, humidity and location data in real time. Modern platforms like CCT’s Smart Solutions combine cellular data loggers, geofencing and predictive analytics. This allows shippers to intervene before excursions occur and supports regulatory compliance.
Sustainability and circular economies
Sustainability is now a core value. Companies are committing to 100 % recyclable or reusable packaging by 2025 and developing plant based films and biodegradable foams. Reusable systems reduce waste and lower carbon footprints, while natural refrigerants and solar powered cold storage cut energy consumption. Manufacturers such as Softbox and va Q tec design products with minimal materials yet long service life.
Growth of pharmaceutical and biologics segments
The rise of biologics, gene and cell therapies, and personalized medicine demands precise temperature control. Portable cryogenic freezers that maintain -80 °C to -150 °C for extended periods and integrate real time monitoring are emerging. Regulatory frameworks like the U.S. FDA’s Drug Supply Chain Security Act and EU Packaging & Packaging Waste Regulation (PPWR) require serialization and traceability, reinforcing the need for smart packaging.
Modernizing infrastructure and last mile delivery
Investments in cold storage warehouses, last mile delivery services and solar powered refrigeration are critical to meet demand in developing regions. For example, solar powered cold rooms enable vaccine distribution in rural areas. Real time route optimization and AI improve last mile efficiency and reduce spoilage.
Frequently asked questions
What temperature ranges do most cold chain packages cover?
Shippers typically fall into four categories: deep frozen (< -60 °C), frozen (-25 °C to -15 °C), refrigerated (2 °C to 8 °C) and controlled room temperature (15 °C to 25 °C). Choose packaging certified for your product’s range and duration.
How long can Cryovac packaged meat last in the freezer?
Cryovac vacuum packaging removes oxygen and extends freezer shelf life; meats can often stay safe for up to 18 months at 0 °F depending on fat content. Always follow manufacturer guidelines.
Do reusable shippers save money?
Yes. While initial costs are higher, reusability reduces per shipment expenses and waste. Market studies show reusable packaging is projected to grow at 10 % CAGR, reaching US $5.8 billion by 2033.
How can I ensure my shipments comply with regulations?
Work with manufacturers who provide GDP and ISTA 7D qualification data and use IATA compliant packaging. Integrated data loggers and digital platforms help document temperature history and support audits.
What is the difference between Cryovac and basic vacuum sealing?
Cryovac is a brand of vacuum sealing that uses specialized high barrier materials and controlled heat sealing to extend shelf life and improve product safety. Basic vacuum sealing typically uses simpler materials and equipment and may not offer the same durability or leak resistance.
Conclusion and recommendations
The cold chain packaging market is evolving rapidly. Key manufacturers such as Sonoco ThermoSafe, Peli BioThermal, Cold Chain Technologies, Sealed Air, va Q tec, and Softbox/CSafe are innovating with reusable systems, high performance insulation and digital monitoring. When choosing a partner, consider temperature requirements, regulatory compliance, sustainability goals and after sales support. Adopt platforms that provide predictive analytics and real time visibility to reduce risk. Finally, stay informed about emerging trends—automation, sustainable materials, and AI will continue to shape the market through 2025 and beyond.
About Tempk
Tempk is a leading provider of end to end cold chain solutions. We combine thermal engineering expertise with cutting edge technologies to design and validate packaging for pharmaceuticals, biotech, food and industrial applications. Our team partners with clients to develop sustainable, cost effective and compliant solutions that protect product integrity. We offer consulting, design, qualification, testing and digital monitoring, enabling you to deliver life saving products with confidence.
Ready to optimize your cold chain? Contact our experts today for tailored guidance, packaging audits or a hands on demonstration of our latest solutions. Together we can ensure every degree matters.
