What is passive cold chain packaging and why does it matter in 2025?
Passive cold chain packaging uses insulation and pre conditioned refrigerants—such as gel packs, phase change materials (PCMs) and dry ice—to maintain product temperatures without an external power source. These systems contrast with active packaging, which relies on mechanical refrigeration or powered heating to regulate temperature, and hybrid solutions that combine active and passive elements. Passive containers are lighter, easier to handle and generally more affordable than active units, making them ideal for short to medium duration shipments where precise temperature control is less critical.
Passive vs active systems: key differences
Passive systems generally have lower acquisition and operating costs, minimal maintenance and a lighter weight, while active systems provide higher temperature accuracy, long duration cooling and greater flexibility at a higher cost. Hybrid systems offer a middle ground but introduce more complexity and cost.
| Attribute | Passive system | Active system | What it means for you |
| Power source | Pre conditioned coolants; no external power | Mechanical refrigeration or dry ice needs power | Passive units are lighter and easier to deploy; active units suit long or ultra cold shipments |
| Temperature accuracy | Moderate; relies on insulation and PCMs | High precision with thermostatic control | Choose passive for moderate ranges; active for narrow tolerance products |
| Cost & weight | Low cost, lightweight | High cost due to electrical components | Passive packaging reduces freight charges and capital investment |
| Setup & maintenance | Simple pre conditioning; minimal maintenance | Complex setup; requires charging and trained personnel | Passive systems can be prepared quickly without specialized skills |
| Typical duration | Hours to several days, depending on PCM and insulation | Several days to weeks with continuous power | Passive solutions suit regional and last mile delivery; active suits intercontinental routes |
Why it matters: The global surge in biologics, meal kit deliveries and e commerce is driving demand for affordable, scalable temperature controlled shipping. Passive packaging accounts for a large share of cold chain shipments because it balances thermal protection with cost and sustainability. For example, the passive temperature controlled packaging solutions market is projected to grow from US$14.9 billion in 2025 to US$30.1 billion by 2035, a testament to its expanding importance across industries.
Everyday analogy
Think of packing ice cream for a picnic. Using a well insulated cooler and plenty of ice packs resembles a passive system—the insulation slows warming, and the ice absorbs heat. Bringing a portable electric freezer is like an active system—it continuously powers cooling regardless of outside conditions. Commercial cold chain packaging follows the same principles but at larger scale and under strict regulatory requirements.
Interactive element: shipment duration estimator
Use a simple decision tool to estimate whether passive packaging suits your shipment:
Identify your product’s safe temperature range and required duration. For instance, vaccines often require 2–8 °C for up to 72 hours.
Check ambient conditions and shipping distance. Passive systems handle moderate temperature swings and regional deliveries; long distance or extreme climates may require hybrid or active solutions.
Select the right PCM and insulation. Use the materials tables below to match your temperature range and duration
Compare estimated total cost and environmental impact. Passive systems generally offer lower shipping costs and a smaller carbon footprint.
How do materials and design impact passive cold chain performance?
Insulation materials: EPS, PUR and vacuum insulated panels
Effective insulation minimises heat transfer, making it central to passive cold chain performance. Expanded polystyrene (EPS) and polyurethane (PUR) are common, affordable foams. EPS is lightweight and cost effective, while PUR offers a higher R value (thermal resistance) for better insulation. Vacuum insulated panels (VIPs) virtually eliminate conduction and convection by creating a vacuum between barrier layers. A VIP system can require up to five times less thickness than EPS to achieve similar thermal performance.
| Material | Thermal performance | Cost & sustainability | Your take away |
| Expanded polystyrene (EPS) | Lightweight, good insulation; typically keeps goods ≤40 °F (4.4 °C) when paired with gel packs | Low cost; limited recyclability but widely available | Suitable for food, meal kits and short duration shipments |
| Polyurethane (PUR) | Higher R value than EPS for better thermal resistance | Moderate cost; some grades recyclable | Ideal for pharmaceuticals needing tighter temperature control |
| Vacuum insulated panels (VIPs) | Superior insulation with thin profile; up to five times the thermal autonomy of foam | Higher cost; increasingly used in reusable systems | Best for ultra cold products (e.g., mRNA vaccines) and long haul shipments |
| Reflective barriers | Reflect radiant heat when combined with other insulators | Lightweight; often made of recyclable aluminum films | Useful in multi layer designs where sunlight exposure is a concern |
Phase change materials (PCMs) and coolant options
Phase change materials absorb or release heat during melting and freezing, providing targeted temperature control. Common PCMs include gel packs, ice packs, dry ice and engineered materials with specific melting points. For example, dry ice sublimates at –78.5 °C and is used for ultra cold shipments, while gel packs maintain moderate ranges (e.g., 0–25 °C) for food and pharmaceuticals. Proper pre conditioning is critical: gel packs must be frozen or tempered to the correct temperature before packing.
| PCM or coolant | Temperature range | Use case | Practical tip |
| Gel packs | 0–25 °C | Meal kits, produce, many pharmaceuticals | Pre freeze to the target range and distribute evenly around product |
| Ice packs | 0 °C and below | Chilled foods and biologics | Combine with insulation to extend duration |
| Dry ice | –78.5 °C (sublimation) | Ultra cold vaccines and gene therapies | Follow safety regulations; vent packaging to release CO₂ |
| Engineered PCMs | Custom melting points (e.g., 2–8 °C, 15–25 °C) | Precise temperature control for vaccines or biologics | Select PCM that matches your product’s safe range; pre condition properly |
Packaging design and sensors
The design of the packaging is as critical as the materials. Customised inserts and sealing methods ensure a snug fit, minimizing void space and preventing movement. Using multi zone shippers allows different temperature zones in one shipment, improving load efficiency by up to 30 %.
Modern passive solutions incorporate sensors and data loggers that record temperatures and send real time alerts when excursions occur. IoT enabled devices provide continuous monitoring and support compliance with regulations such as the U.S. Food Safety Modernization Act (FSMA) and the Drug Supply Chain Security Act (DSCSA). Integrating sensors helps detect issues early, preventing product loss.
Which industries benefit most from passive cold chain packaging?
Passive cold chain solutions support diverse sectors by ensuring product quality, reducing waste and enabling global trade. Below are the major industries and why they rely on passive systems.
Pharmaceuticals and biologics
Vaccines, insulin, monoclonal antibodies and gene therapies require strict temperature control—often 2–8 °C or even –80 °C. The World Health Organization estimates that more than one quarter of vaccines arrive with reduced efficacy due to cold chain failures. Passive packaging using VIPs and PCMs prevents degradation and supports regulatory compliance. For example, vacuum insulated panels combined with dry ice are essential for mRNA vaccines, while expanded polystyrene paired with gel packs maintains 0–25 °C for other biologics.
Food and beverage
Passive cold chain packaging preserves freshness and nutrition in perishables such as meat, dairy, produce and meal kits. Temperatures must stay at ≤40 °F (4.4 °C) to prevent microbial growth. Chocolate softens at 29 °C and melts at 34 °C, requiring thermal mailers with reflective insulation. Meal kit services use passive systems to maintain temperatures for 24–72 hours at an affordable cost.
Agriculture and horticulture
Seeds, flowers and plants are sensitive to temperature and humidity. Cold chain packaging ensures vitality during transit and enables global trade for cut flowers and tropical fruits. Breathable materials and controlled humidity can preserve leafy greens with relative humidity up to 95 %.
Chemical, cosmetic and other industries
Certain chemicals, cosmetics and specialty products degrade when exposed to heat. For example, high quality cosmetics may lose consistency or active ingredients if temperatures exceed recommended ranges. Passive packaging protects these products by maintaining stable temperatures during transit.
E commerce, clinical trials and last mile delivery
The rise of e commerce and meal kit services has increased demand for passive solutions that offer affordable shipping for 24–72 hours. Clinical trial samples and specialty foods also rely on passive systems for predictable timelines and cost sensitive operations. Lightweight construction reduces freight charges, making passive packaging attractive for last mile deliveries.
Industry requirements and packaging types
| Product type | Safe temperature range | Typical passive packaging | Meaning for you |
| Vaccines & biologics | 2–8 °C; ultra cold ≤–80 °C | VIP containers with dry ice or PCMs; tamper evident seals | Ensures efficacy and patient safety for pharmaceuticals |
| Perishable foods | ≤4.4 °C | EPS or PUR boxes with gel packs; breathable liners | Prevents spoilage and preserves taste and texture |
| Chocolate | 29–34 °C (softening & melting) | Thermal mailers with reflective insulation; moderate cooling | Maintains appearance and prevents fat bloom |
| Frozen foods | –30 °C–0 °C | PUR containers with dry ice or –20 °C PCMs | Prevents thawing of seafood and ice cream during long transit |
| Ultra cold biologics | ≤–80 °C | VIPs combined with dry ice or reusable rigid containers | Essential for mRNA vaccines and gene therapies |
Challenges and best practices for passive cold chain packaging
Common challenges
Limited duration and risk of delay: Passive systems provide finite thermal autonomy; shipments delayed beyond PCM capacity risk spoilage.
Temperature excursions: Passive systems offer moderate temperature accuracy and are more susceptible to ambient fluctuations.
Pre conditioning requirements: Gel packs and PCMs must be conditioned to the correct temperature before packing, which requires time and freezer space.
Void space and humidity: Empty spaces accelerate heat transfer and allow contents to shift; humidity can affect leafy produce.
Regulatory compliance: Documentation and monitoring are needed to meet FSMA, DSCSA and Good Distribution Practice standards.
Best practices and practical tips
Match product requirements to temperature zones: Classify products into cool (10–15 °C), refrigerated (0–10 °C), frozen (–30–0 °C) or ultra cold (≤–80 °C) zones. This ensures the correct PCM and insulation are used.
Pre condition refrigerants properly: Freeze gel packs or condition PCMs at the required temperature before packing. Under conditioning reduces thermal performance.
Minimise void space: Fill empty areas with cushioning or insert trays to reduce air pockets and keep contents stable.
Control humidity: Use absorbent liners or moisture regulating materials for produce that requires high relative humidity.
Incorporate sensors and documentation: Use temperature loggers and IoT devices to record and transmit data. Attach clear labels (e.g., “Keep Frozen”) and maintain records for regulatory audits.
Plan for contingencies: For shipments exceeding the typical 72–96 hour window, consider hybrid systems or include contingency gel packs. For example, pallet sized passive containers can maintain conditions for up to 120 hours.
Real world example
Clinical trial shipments: A pharmaceutical distributor shipped insulin pens and biologic samples across regional networks. By using pre conditioned passive containers and proper packing techniques, they avoided the high capital costs of active shippers, reduced freight charges and maintained temperature integrity over 48 hours. The simplicity of passive systems enabled staff to prepare shipments without specialized training, improving profitability.
2025 trends and innovations in passive cold chain packaging
Market growth and segment insights
The cold chain packaging sector is expanding rapidly. The global cold chain packaging market is projected to grow from US$27.7 billion in 2025 to US$102.1 billion by 2034, a robust CAGR of 15.6 %. Passive packaging is a major contributor—insulated shippers are expected to hold 55 % of the passive packaging market in 2025. Key market drivers include:
Pharmaceutical demand: The global pharmaceutical cold chain, valued at nearly US$65 billion in 2025, is set to double within a decade, driven by biologics and advanced therapies. The U.S. pharmaceutical cold chain packaging market alone is projected to grow from US$4.9 billion in 2025 to US$13.8 billion by 2035.
Reusable and sustainable systems: The shift from single use EPS to reusable and recyclable packaging is accelerating. Companies like Sonoco, Peli BioThermal and Cold Chain Technologies are investing in recyclable materials and reusable pallet shippers.
Regional highlights: North America holds about 36 % of the market due to strong pharmaceutical and e commerce industries; Europe advances sustainability and circular economy regulations; Asia Pacific is the fastest growing region driven by vaccine production and a rising middle class.
Technological innovations
Advanced insulation and bio materials: VIPs and aerogel based panels offer superior thermal performance and reduce shipping weight; newer bio based foams (e.g., mushroom or algae derived) are biodegradable. Aerogel VIPs can reduce shipping costs by up to 70 %.
Smart monitoring and IoT: Real time sensors and 5G trackers provide continuous temperature, humidity and shock data, allowing corrective actions before product quality suffers. Blockchain adoption is emerging for provenance and compliance verification.
AI optimized designs: Artificial intelligence and automated thermal modelling are being used to reduce package weight while maintaining performance.
Pooling networks and rental models: Reusable container pooling reduces capital expenditure and environmental impact. Rental services with integrated data loggers allow businesses to pay per use, aligning with circular economy principles.
Sustainability and regulatory drivers
Sustainability is a top priority. Regulations like the EU Packaging and Packaging Waste Regulation (PPWR) mandate higher recyclable and reusable content. The FSMA Rule 204 requires 24 hour traceability for high risk foods, and the DSCSA imposes serialization and documentation requirements for pharmaceuticals. These frameworks encourage businesses to adopt passive packaging with recycled content, integrate tracking, and document temperature history.
Frequently asked questions about passive cold chain packaging
Q1: What is the difference between active and passive cold chain packaging?
A: Active packaging uses mechanical refrigeration or electrical systems to maintain temperature, providing high precision but at a higher cost. Passive cold chain packaging relies on insulation and pre conditioned coolants like gel packs or PCMs to maintain temperature without external power. This makes passive systems lighter and more affordable, but their cooling duration is limited.
Q2: How long can passive cold chain packaging maintain temperature?
A: Duration depends on the insulation, PCM type and ambient conditions. Many passive packages can maintain target temperatures for 24–72 hours, while pallet sized units with VIPs and dry ice can hold ultra cold temperatures for up to 120 hours. Pre conditioning refrigerants and minimizing void space extend performance.
Q3: Are passive systems suitable for shipping vaccines and biologics?
A: Yes. When designed properly, passive systems using VIPs and appropriate PCMs can maintain the strict 2–8 °C range required by most vaccines. However, ultra cold products (≤–80 °C) may need VIPs with dry ice or hybrid systems to ensure extended duration..
Q4: What materials are most sustainable for passive cold chain packaging?
A: Recyclable materials such as certain foams (e.g., polyethylene), paper based insulation and reusable VIP containers are increasingly available. Some manufacturers use bio derived foams or plant based gel packs. Choosing reusable systems and participating in pooling networks also reduces waste.
Q5: How do I choose the right passive packaging for my shipment?
A: Identify your product’s safe temperature range and required duration, select the appropriate PCM, and consider factors such as shipping distance, ambient conditions, regulatory requirements and sustainability goals. Consulting a cold chain expert or using a shipment calculator can help optimize your choice.
Summary and recommendations
Passive cold chain packaging offers a cost effective, lightweight and reliable solution for maintaining temperature integrity during shipping. By using insulation and pre conditioned coolants, these systems protect pharmaceuticals, foods, plants and chemicals without external power. Choosing passive systems reduces shipping costs and environmental impact while supporting compliance with FSMA, DSCSA and EU PPWR regulations. Key takeaways include:
Understand the differences among passive, active and hybrid systems; choose passive when moderate temperature accuracy suffices and shipments are short to medium in duration.
Match insulation and PCM materials (EPS, PUR, VIPs) to your product’s temperature range and duration.
Follow best practices—pre condition coolants, minimise void space, use sensors and documentation—to maximise performance.
Monitor market trends; adopt reusable, IoT enabled packaging and AI optimised designs to stay competitive in 2025 and beyond.
Next steps
Audit your product portfolio: Identify products by temperature zone and shipping duration; determine which shipments can use passive systems.
Engage with experts: Reach out to cold chain specialists to select materials (EPS, PUR, VIPs, PCMs) and decide between single use or reusable packages.
Implement monitoring: Adopt sensors and data loggers for real time tracking; consider blockchain for traceability.
Plan for sustainability: Evaluate life cycle impacts, choose recyclable or reusable materials, and participate in pooling networks to reduce waste.
Stay compliant: Keep abreast of regulatory updates (FSMA, DSCSA, PPWR) and ensure documentation is thorough.
About Tempk
Tempk is a specialist in cold chain packaging solutions, offering a comprehensive range of insulated boxes, ice packs, thermal bags and reusable containers designed for food, pharmaceuticals and other temperature sensitive goods. Our research and development centre focuses on smart, sustainable packaging innovations, including vacuum insulated panels, advanced PCMs and eco friendly fibres. We provide tailored designs and validation reports to help clients navigate complex regulatory landscapes and achieve sustainability goals.
Call to action: Interested in optimising your shipments? Contact Tempk’s advisors to discuss customised passive cold chain packaging solutions that balance cost, performance and sustainability.
