Updated: November 20, 2025
Cold chain packing ensures that vaccines, biologics, fresh foods and specialty chemicals arrive at their destinations intact. Without it, up to 20 % of temperature sensitive pharmaceuticals are compromised during transit and the global food industry loses US $35 billion annually due to poor temperature control. This guide explains what cold chain packing is, how to choose materials such as phase change materials (PCM) or dry ice, and which trends are reshaping the industry in 2025. You’ll learn why the global cold chain packaging market is set to grow from US $30.88 billion in 2025 to US $64.49 billion by 2032 and discover practical tips to keep your shipments compliant and sustainable.
What is cold chain packing and why does it matter? Discover how proper insulation and refrigerants prevent spoilage and why vaccines, seafood and meal kits depend on tight temperature control.
How do you select the right cold chain packing materials? Compare phase change materials and dry ice and learn to choose based on temperature range, transit duration and regulatory requirements.
What are the latest innovations in cold chain packing for 2025? Explore trends like AI driven monitoring, sustainable materials and reusable solutions, and see how they can benefit your business.
How can you ensure compliance and follow best practices? Understand Good Distribution Practice (GDP) guidelines, preconditioning, monitoring and documentation to avoid costly excursions.
What are common questions about cold chain packing? Get clear answers to frequently asked questions about packaging types, market size and regulatory considerations.
What is cold chain packing and why does it matter?
Cold chain packing is the combination of insulated containers, refrigerants and monitoring devices that keep products within strict temperature bands during transport. When shipping vaccines, biologics or fresh produce, even a small temperature excursion can destroy quality. According to industry research, up to 20 % of temperature sensitive pharmaceuticals are compromised during transit and the global food sector loses US $35 billion each year due to inadequate cold chain control. These losses translate into wasted resources, recalls and potential health risks. With the global cold chain packaging market valued at US $28.14 billion in 2024 and projected to reach US $64.49 billion by 2032, proper packing is not just a regulatory requirement—it’s a competitive advantage.
Why temperature control is critical
Temperature control preserves the potency and safety of products. Vaccines often require storage between 2 °C and 8 °C, and gene therapies may need –80 °C conditions. When packages fall outside these ranges, the active ingredients degrade. For foods like seafood and dairy, uncontrolled temperatures allow bacterial growth and spoilage, leading to waste and safety concerns. Cold chain packing bridges the gap between production and consumption by creating a thermal envelope that shields products from ambient conditions.
Understanding temperature categories for cold chain packages
Different products demand different temperature bands. The table below summarizes the primary categories, their typical ranges and what they mean for you:
| Temperature Category | Typical Range | Suitable Products | Practical Meaning |
| Ultra low | –20 °C to –80 °C | mRNA vaccines, gene therapies, biological samples | Requires high performance insulation (e.g., vacuum insulated panels or dry ice) capable of holding ultra cold temperatures for at least 96 hours. |
| Refrigerated | 2 °C to 8 °C | Vaccines, insulin, fresh produce | This common range uses phase change materials engineered for 5 °C and validated to GDP standards; look for packages offering 48–96 hours of protection. |
| Controlled room temperature (CRT) | 15 °C to 25 °C | Oral medicines, certain biologics | These packages use lighter insulation and PCMs designed around 22 °C and are ideal for short distances or moderate climates. |
Practical tips and advice
Short distance food delivery: For meal kits and groceries shipped locally, choose lightweight insulated mailers with gel packs or biodegradable liners. This reduces waste and maintains freshness without heavy refrigerants.
Clinical samples and biologics: When shipping clinical samples or biologics over several days, use validated shippers with PCMs calibrated to the required range. Precondition the refrigerants and assemble packages in temperature controlled rooms to avoid pre departure excursions.
Multi stop routes or variable climates: For shipments that cross multiple climates or involve stops, integrate smart sensors and AI driven monitoring. Predictive analytics can detect temperature drift and trigger route adjustments before spoilage occurs.
Real case: During the COVID 19 vaccine rollout, Cold Chain Technologies supplied more than 500 million vaccine doses using reusable shippers. Their Smart Solutions platform combined AI and IoT to recommend packaging based on duration, temperature range and weather, reducing thermal excursions and minimizing waste.
How do you select the right cold chain packing materials?
Choosing appropriate materials balances temperature needs, transit duration, regulatory compliance and sustainability. Phase change materials (PCMs) and dry ice are the most common refrigerants, each with distinct advantages.
Direct answer: PCMs vs. dry ice
PCMs absorb and release heat at predefined temperatures to maintain stable ranges—such as 2 °C to 8 °C or –20 °C. They are reusable, classified as non hazardous and reduce shipping restrictions. Dry ice, on the other hand, is solid carbon dioxide that sublimates at –78.5 °C, delivering ultra cold conditions for deep frozen biologics but requiring hazardous materials labeling and proper venting. Use PCMs when you need controlled temperatures above –20 °C, and choose dry ice for shipments requiring –70 °C or colder.
Expanded explanation
When selecting materials, consider the following:
Target temperature and shipment duration: PCMs are engineered for specific ranges. They work well for vaccines (2 °C–8 °C) or frozen goods (–20 °C) up to about 72 hours. Dry ice is ideal for ultra cold shipments (below –70 °C) up to 96 hours but is single use and requires careful handling.
Regulatory complexity: Dry ice falls under IATA, DOT and UN hazardous materials rules, requiring documentation and labeling. PCMs generally avoid hazardous labeling but must comply with temperature data logging requirements.
Cost and sustainability: PCMs require higher upfront investment but offer long term savings through reuse and reduced waste. Dry ice is inexpensive per shipment yet incurs recurring costs and contributes to CO₂ emissions.
Durability: PCMs come in durable gel or wax forms and resist punctures, making them suitable for multiple shipments. Dry ice packs are single use and must be packed in ventilated containers to allow gas release.
Comparing refrigerants: a quick reference table
| Packaging Type | Typical Range | Best Use Cases | Practical Considerations |
| Phase Change Materials (PCMs) | +2 °C to –20 °C | Vaccines, biologics, reagents, clinical trial kits | Reusable, non hazardous, requires preconditioning; higher upfront cost but lower long term cost |
| Dry Ice | Below –70 °C | Ultra cold biologics, CRISPR materials, frozen cells and plasma samples | Single use, requires hazardous labeling and venting; lower initial cost but higher recurring cost |
| Hybrid Solutions | Combined PCM and dry ice | Mixed loads requiring different temperature zones | Integrate PCMs around moderate temperature items and dry ice for ultra cold products in the same shipper |
Practical tips and advice
Short journeys with controlled temperatures: Use PCMs for shipments under 72 hours when temperatures are between 2 °C and 8 °C. Precondition the PCM packs to the target temperature and pack them evenly around the product.
Deep freeze shipments over several days: Choose dry ice or hybrid solutions. Ensure containers allow carbon dioxide to vent and comply with hazardous materials labeling.
Regulation heavy shipments: If you want to simplify compliance, select PCMs. When using dry ice, ensure staff are trained in IATA and DOT regulations and that carriers are aware of the shipment’s classification.
Industry example: A biotech firm switched from gel packs to PCM containers and experienced no temperature failures while reducing costs by 40 % after ten shipments. A gene therapy company using dry ice shippers cleared customs smoothly after receiving validated protocols and hazard training.
What are the latest innovations in cold chain packing for 2025?
The cold chain industry is evolving rapidly thanks to technological, environmental and logistical drivers. In 2025, several trends redefine how cold chain packing is designed and executed.
Trend overview
- AI driven visibility and predictive analytics:Artificial intelligence and data analytics provide real time insights into temperature, location and potential risks. These tools transform reactive logistics into proactive management, allowing shippers to intervene before a temperature excursion occurs. Advanced sensors, blockchain and smart contracts further enhance traceability and streamline last mile delivery.
- Sustainability and green logistics:Consumer demand for sustainable products is reshaping packaging design. More than 55 %of global consumers prefer foods packaged with sustainability claims, with higher percentages in Brazil (74 %), Mexico (66 %) and India (67 %). Companies respond by adopting eco friendly refrigerants, recyclable materials and reusable packaging. Phase change materials and biodegradable foams reduce waste and carbon emissions, while renewable energy and electric trucks lower operational footprints.
- Advanced insulation and phase change materials:Vacuum insulated panels (VIPs) offer 5–10 timesthe insulation of expanded polystyrene (EPS), enabling thinner and lighter packages. PCMs are tailored for specific ranges—such as –20 °C for frozen goods or 5 °C for vaccines—and arranged in multi layer designs to form thermal envelopes.
- Digitalization and data platforms:Integrated data platforms unify order management, package selection and real time monitoring. These systems support compliance with GDP, IATA and FSMA regulations, optimize routes, reduce energy consumption and enable accurate carbon footprint reporting.
- Automation and robotics:To address labor shortages and improve efficiency, warehouses are adopting automation. Half of warehouses are expected to employ autonomous mobile robots within the next decade, and 10–20 %may install automated storage and retrieval systems. Automation streamlines picking, packing and inventory management, reducing human error and boosting throughput.
Latest progress at a glance
Predictive monitoring: AI algorithms analyze sensor data to forecast potential temperature excursions and suggest corrective actions.
Reusable packaging growth: Reusable cold chain systems are projected to grow from US $4.97 billion in 2025 to US $9.13 billion by 2034, reflecting a shift toward circular economy models.
Expansion in emerging markets: The Asia Pacific cold chain logistics market is projected to grow from US $142.71 billion in 2023 to US $215.43 billion by 2028. Europe holds 33.58 % of the cold chain packaging market share, driven by strong demand for biologics and vaccines.
Market growth: Analysts expect the global cold chain packaging market to rise from US $30.88 billion in 2025 to US $64.49 billion by 2032. Another report estimates the broader cold chain market could surpass US $410 billion by 2028.
Sustainable consumer preferences: Eco conscious buyers influence packaging decisions. Surveys show that 43 % of purchasers consider environmental impact when choosing packaging.
Market insights
The global cold chain packaging market is on an upward trajectory. In 2024 the market was valued at US $28.14 billion, rising to US $30.88 billion in 2025 and projected to reach US $64.49 billion by 2032. Europe dominates with 33.58 % share due to robust demand for biologics and vaccines, while Asia–Pacific experiences the fastest growth, spurred by expanding pharmaceutical sectors and e commerce adoption. Growth drivers include increasing demand for temperature sensitive pharmaceuticals and biologics, the proliferation of ready to eat meals and frozen foods, and the integration of smart and IoT enabled packaging. The primary restraints are high costs associated with advanced materials and infrastructure and the risks of temperature excursions due to supply chain disruptions. However, opportunities arise from the adoption of sustainable materials and biodegradable plastics.
How can you ensure compliance and follow best practices?
Compliance isn’t optional—regulatory bodies like the EMA, FDA and WHO enforce strict guidelines for transporting temperature sensitive goods. Good Distribution Practice (GDP) guidelines lay out the core principles for cold chain management, ensuring quality and safety from manufacturer to patient.
Direct answer: essential compliance principles
GDP guidelines require medicines to remain within their specified temperature ranges (often 2 °C–8 °C), transported in qualified equipment, monitored continuously and documented thoroughly. Risk management plans identify potential hazards, and trained personnel implement corrective measures when excursions occur. Other standards, such as USP <1079> and 21 CFR Part 11, govern packaging validation and data integrity, while IATA rules cover the handling of dry ice and hazardous materials.
Expanded explanation
Cold chain compliance involves a combination of technology, process and people:
Preconditioning: Refrigerants must be chilled or frozen to the target temperature before packing. Assemble packages in temperature controlled environments to prevent pre shipment excursions.
Monitoring: Use data loggers or IoT sensors to record temperature, humidity and location during transit. Real time visibility helps intercept problems before they become critical.
Documentation: Maintain clear records of temperature data, handling procedures and corrective actions to demonstrate compliance during audits.
Training: Ensure that staff understand GDP requirements, emergency procedures and proper handling protocols. Training should cover minimizing exposure to ambient temperatures and using correct equipment.
Continuous improvement: Conduct regular audits to identify gaps, update SOPs and implement new technologies that enhance reliability.
Best practices table
| Best Practice | Description | Benefit |
| Precondition refrigerants | Chill gel packs or PCMs to the required temperature before packing | Prevents heat influx during assembly and ensures the shipper starts at the correct temperature. |
| Use validated packaging | Select insulated containers tested for your temperature range and duration (e.g., 48–96 hours) | Demonstrates compliance and reduces risk of excursions. |
| Integrate IoT monitoring | Employ sensors and data loggers that transmit real time temperature and location data | Enables proactive interventions and documentation for audits. |
| Train personnel | Educate staff on GDP, IATA and hazardous material regulations | Ensures proper handling, loading and emergency response. |
| Review and refine | Perform periodic audits, review temperature data and update procedures | Drives continuous improvement and reduces long term risk. |
Practical tips and advice
Pack in layers: Place PCMs or gel packs evenly around products to create a uniform thermal envelope. Avoid dead space that allows heat pockets.
Validate your packaging: Choose packaging validated by third parties or regulatory bodies; ask for thermal performance reports and qualification data.
Plan return logistics: For reusable systems, establish return paths and cleaning processes. The reusable cold chain packaging market was valued at US $2.5 billion in 2024 and is expected to double by 2033.
Example: A carrier pre cooled PCM packs in a temperature controlled warehouse, packed vaccines within 30 minutes to avoid heat exposure and used data loggers for real time monitoring. The shipment remained within 2 °C–8 °C for 72 hours despite ambient temperatures above 30 °C. Such discipline reduces spoilage and meets compliance standards.
Frequently Asked Questions
Q1: What is the difference between cold chain packing and cold chain logistics?
Cold chain packing focuses on the materials and techniques used to keep products at the correct temperature during transit. Cold chain logistics is the broader system—including transportation, warehousing and monitoring—that ensures temperature controlled products move safely from origin to destination.
Q2: How do phase change materials work?
PCMs absorb heat as they melt and release heat as they solidify, maintaining a narrow temperature band. They can be engineered for specific ranges—such as 2 °C–8 °C or –20 °C—and are reusable and non hazardous.
Q3: When should I use dry ice instead of PCM?
Use dry ice for ultra cold shipments requiring temperatures below –70 °C, such as CRISPR materials and certain gene therapies. Dry ice is single use and requires hazardous materials labeling, so plan accordingly.
Q4: What are the biggest drivers of cold chain packaging market growth?
Market growth is driven by rising demand for biologics and vaccines, expansion of ready to eat foods and e commerce, and regulatory pressures for quality and safety. The market is projected to grow from US $30.88 billion in 2025 to US $64.49 billion by 2032.
Q5: Are reusable cold chain packages worth the investment?
Reusable packages have higher upfront costs but lower lifetime expenses due to multiple use cycles. They reduce waste and align with sustainability goals. The reusable market is expected to double between 2024 and 2033.
Q6: How can I make my cold chain operations more sustainable?
Use recyclable or biodegradable materials, adopt reusable containers, optimize route planning to reduce fuel consumption and integrate data platforms to monitor and minimize energy use. Surveys show 43 % of consumers factor environmental impact into purchasing decisions.
Summary and recommendations
Cold chain packing is the backbone of safe and effective delivery for vaccines, biologics, fresh foods and specialty chemicals. As of 2025, the market is poised for rapid growth, driven by the increasing demand for temperature sensitive products and innovations in AI driven monitoring and sustainable materials. To protect your shipments, choose materials based on temperature range, duration and regulatory complexity; precondition refrigerants; and integrate real time monitoring. Invest in reusable systems and eco friendly materials to reduce waste and meet rising consumer expectations for sustainability. Stay current with regulations and train your team on best practices—compliance not only avoids penalties but also protects your brand.
Next steps and call to action
Assess your product’s requirements. Identify the exact temperature range and hold time needed.
Choose the right materials. Select PCMs, dry ice or hybrid solutions based on the criteria in this guide.
Implement monitoring. Adopt IoT sensors and predictive analytics to gain real time visibility and proactive control.
Invest in sustainability. Evaluate reusable packaging and biodegradable materials to reduce waste and support your environmental goals.
Consult experts. Work with a qualified cold chain partner to design, validate and optimize your packaging solutions.
About Tempk
Tempk is a leading provider of cold chain packaging solutions. We design and manufacture insulated boxes, phase change materials, gel packs and smart sensors that keep your products within precise temperature ranges during transit. Our research and development team constantly innovates with sustainable materials, such as biodegradable foams and recyclable VIP panels, to reduce environmental impact. We support clients across pharmaceuticals, food and industrial sectors with validated packaging, AI driven monitoring and regulatory expertise. With a commitment to quality and sustainability, we help you deliver temperature sensitive goods safely and efficiently.
Ready to optimise your cold chain? Contact Tempk for a consultation and discover how our solutions can protect your products, reduce waste and improve your bottom line.
