Tag Archives: thermosafe

Sonoco ThermoSafe Introduces the Pegasus ULD line of Passive Temperature Controlled Unit Load Devices

Sonoco ThermoSafe announced the creation of the Pegasus ULD® line of passive temperature controlled unit load devices.  The Pegasus ULD will be the first passive bulk temperature-controlled container for pharmaceutical use that is an approved unit load device, which allows it to speed through existing international ground handling and customs processes at the lowest possible cost.

With increasing demands for life science and healthcare companies to ship in larger quantities, the Pegasus ULD was specifically designed to fulfill a gap in the market for passive bulk packaging solutions. Engineered with composite materials, the unit load device will offer a lighter solution that is substantially more damage-resistant than traditional metal containers. Additionally, Sonoco ThermoSafe customers will experience cutting edge integrated real-time data capabilities, including internal and external temperature tracking and robust geolocation. Because risk mitigation decisions are based on accurate and timely data, Pegasus ULD users will be able to count on these capabilities when they need them the most.

To create the Pegasus ULD, Sonoco ThermoSafe signed a long-term exclusive development and manufacturing agreement with AEROTUF, a leading supplier of innovative composite ULD containers (www.aerotuf.com).  The partnership combines ThermoSafe’s expertise in thermal engineering and pharmaceutical logistics with AEROTUF’s materials science and aeronautical engineering capabilities. The first Pegasus ULD model, to be launched in the upcoming months, will be the lighter AKP size, which fits a full US pallet and shares the same footprint of the AKE size without the imbalanced overhang section which accounts for over 80% of transit damage in AKE/RKN containers.

“We are delighted to partner with AEROTUF to create the best-in-class Pegasus ULD® line of passive temperature control ULD containers,” said Christopher Day, Director of Marketing, Innovation and Business Development for Sonoco ThermoSafe. “The rugged, lightweight composite design of this unit load device enables the pharmaceutical supply chain to cost-effectively ship globally across the Americas, EMEIA and Asia-Pacific regions. Additionally, Sonoco’s 300+ global locations allow the ThermoSafe division to quickly and efficiently expand the depot network for leasing Pegasus ULD® units across the globe.”

Additional announcements about the Pegasus ULD, including airline approvals and updates to the global service network, will be forthcoming. Please contact your Sonoco ThermoSafe representative or visit www.thermosafe.com/contact for more information.

Sonoco ThermoSafe and AirBridgeCargo Airlines Launch Global Partnership to Lease PharmaPort 360 Temperature Controlled Bulk Shippers

Pictured at LogiPharma 2019 in Switzerland: Christopher Day, ThermoSafe Director of Business Development & Innovation with Yulia Celetaria, AirBridgeCargo Regional Pharma Manager Europe and David Beecham, AirbridgeCargo Product Development Director.

Sonoco ThermoSafe and AirBridgeCargo Airlines (ABC), one of the leading cargo carriers in the transportation of special cargoes, announced a global partnership agreement for the leasing of the PharmaPort® 360 temperature controlled shipping container. The agreement will enable pharmaceutical shippers to lease PharmaPort® 360 containers directly from AirBridgeCargo Airlines.

The PharmaPort® 360 utilizes proprietary hybrid technology to provide extremely precise, long duration +5C temperature control for transporting high value cargo for the world’s leading biopharmaceutical companies. Once charged, the PharmaPort® functions like an active temperature controlled container without the energy consumption, heat discharge or temperature variability of other compressor-based technologies. The PharmaPort’s hybrid technology allows it to operate on battery power substantially longer than competing active units used for bulk air shipments, and it also eliminates the need for refrigerated trucks for lengthy truck lanes. Additionally, the PharmaPort® 360 is the only container in the industry that contains a fully integrated, FAA (Federal Aviation Administration) approved telemetry system, providing real-time, cloud-based data on payload and ambient temperature and key mechanical components, precisely synchronized with GPS location.

“We have been consistently developing and upgrading our ABC pharma, offering our customers dedicated airlift for both passive and active ways of transportation. With PharmaPort® 360 being available for lease, we can guarantee much-needed air freight solution for pharmaceutical goods with precise temperature mode conditions and requirements to maintain an internal environment of 5°C. This is a quantum leap for our dedicated product, and we expect it to ramp up our volumes, as well as to gain interest in our services from new customers,” said Fedor Novikov, Deputy Director, Products of AirBridgeCargo Airlines.

“We are very pleased to have this important agreement with AirBridgeCargo Airlines. Their focus on specialized temperature controlled cargo fits perfectly with the specialized thermal and data technology in the PharmaPort® 360,” said Christopher Day, Director of Business Development & Innovation at Sonoco ThermoSafe. “As always, our focus is to make it as easy as possible for pharmaceutical shippers and forwarders to directly lease PharmaPort® 360s from the leading airlines around the globe, and we are delighted to partner with AirBridgeCargo Airlines to do so.” Visit www.thermosafe.com/pharmaport to learn more.   

Breathing New Life Into The Cold Chain

Transporting temperature-sensitive and critical life sciences products by air has been fraught in the past, given these products have a strict temperature range that cannot be breached. Exposure to divergent temperature ranges en route through airports was always a challenge.

Cathay Pacific Cargo is working with suppliers to offer a range of shipping solutions that use new technologies. They have been designed to meet life-science’s ever more complex and precise cold-chain demands and regulations.

One of the most recent of these partnerships is with Sonoco ThermoSafe and its PharmaPort 360 container solution. Through its patented technology, PharmaPort 360 offers the reassurance of ‘active’ container products alongside the cost efficiencies of passive  products. One of its prominent features is live telemetry recordings of location and temperature, accessible to shippers.

The PharmaPort 360 is also incredibly easy to operate – it requires a 12-hour charge for the container to operate to its full potential and has few complex moving parts.


PharmaPort 360 doesn’t use traditional refrigeration methods, but rather a patented system with a hot and cold plate. It can be fully charged in 12 hours and offers a stable internal temperature of 5°C for up to 72 hours when the container is in an ambient temperature of 30°C. ‘It can add flexibility to journey times and routings,’ says Gary Sze, Cathay Pacific Cargo Products Manager.

As soon as the PharmaPort 360 is charged and unplugged from the electrical supply, the internal temperature is maintained by a constantly running fan that circulates air from the stored thermal energy of the plates. The plates are exposed from behind insulated vacuum panels as and when required.

‘This enables us to be super- precise in terms of temperature,’ says Chris Day, Director of Global Business Development at Sonoco ThermoSafe. ‘Because the fan is always on, the temperature gradient is smoother than containers that use compressors, which requires spikes of energy and create more of a zig-zag temperature profile over the course of the shipment,’ he adds.


Unlike compressor boxes, PharmaPort 360 boxes do not exhaust hot air and they can therefore be stored next to perishable shipments and transported in an ambient truck, which can help keep costs down. They are also solidly built and have fewer moving parts than some active containers.

In other products, temperature excursions are usually caused by mechanical failures, such as a refrigeration compressor failing or because of a human element. ‘It might be that it’s not programmed properly,’ says Sze. But, as the PharmaPort 360 is set to operate to one temperature (at 5°C, which covers 80 percent of biotech shipments) it doesn’t require programming. ‘You simply plug it in and unplug it before shipping – that’s it,’ adds Sze. It travels with a bag of 10 different adaptors and can use any local power supply.


PharmaPort 360 proves its reliability by transmitting data from its integrated network of sensors. Sonoco ThermoSafe’s Day says: ‘The sensors capture and transmit data all the time – the temperature inside, the ambient temperature outside the container, plus GPS positioning and all the mechanical functions, such as battery life, and the energy levels in the thermal plates.’

The in-air segment is not transmitted due to inflight regulations, but there’s a solution for this too, as Cathay’s Sze explains: ‘PharmaPort 360 is approved by the FAA because each is fitted with an accelerometer, altimeter and an algorithm that can detect when the aircraft is taking off. At takeoff, transmission stops but recording continues. On landing, the transmitter is switched back on and a batch transmission is sent out.’

PharmaPort 360’s data is dense and accessible. Day says: ‘We can replay every trip and if there are investigations, we can get answers in minutes rather than months, and we keep the data for five years.’Cathay Pacific’s Sze says: ‘This product is a generation ahead. We’re proud to offer this innovative product to our customers.’

This article was originally published in the February 2019 issue of Pharmaceutical Manufacturing and Packing Sourcer.  Click the link to access to full feature: http://edition.pagesuite-professional.co.uk/html5/reader/production/default.aspx?pubname=&edid=f48356d6-bff9-4ba4-82ea-30c8001c14dd&pnum=19 .

Sonoco ThermoSafe Survey Reveals Future Needs, Trends of Cold Chain Industry

ARLINGTON HEIGHTS, Ill.- Sonoco ThermoSafe, a unit of Sonoco (NYSE:SON) and a leading global provider of temperature assurance packaging, revealed the results of its survey entitled “Assessing the Future of the Cold Chain Industry” at the 12th annual Cold Chain Global Forum in Boston on Oct. 9, 2014.

Continue reading

ThermoSafe Publishes Case Study on Solving Logistical Challenges Through Reclamation

The study details how ThermoSafe and its reclamation partner, CTS was able to solve major logistical challenges for Comprehensive Health Services, a provider of medical services to governmental agencies in the Middle East and other International locations. Click here to download the case study.

Alternatively, you can click here to read the study on page 30 of the September/October issue of Pharmaceutical Commerce.

Sonoco ThermoSafe Introduces New 30 Liter Size to Certis Ready-Engineered Solutions

Sonoco ThermoSafe’s line of Certis ready-engineered solutions are used world-wide to ensure our customers’ temperature sensitive products maintain efficacy throughout the supply chain. Based on market demand for larger payloads, we leveraged the component commonality of the modular Certis platform to create a 30 liter, 2 day, refrigerated solution. Continue reading

Media Partners Offer a First Look at Cold Chain Industry Survey Results

ThermoSafe recently conducted a forward looking cold chain industry survey.   Three of our media partners published a preview of the results prior to the full release at the 2014 Cold Chain Global Forum Conference in Boston on October 2nd.

Click the links below to view the articles.


Healthcare Packaging

Pharmaceutical Commerce

Stages of New Drug Development

Many people do not realize the amount of time and money it takes to take a commercial drug to market.  Here are some key things to remember:

  • Drug development is a very long process, the costs are extremely high, and the chance of success is very low
  • If a drug becomes commercialized, a lot is then riding on its success.
  • Our customers invest all of that time and money into getting the drug to market so cutting corners on a temperature controlled shipper can prove risky and in the end, costly.

Here is a very helpful graph from FDAReview.org that maps out the process:

Investigational New Drug Application
Phase I
Phase II
Phase III
New Drug Application
Phase IV / Postmarket surveillance
Safety dosing efficacy

Safety efficacy side effects

$15.2 million
$23.4 million
$86.5 million
21.6 months
25.7 months
30.5 months
1 to 6 years
6 to 11 years
0.6 to 2 years
11 to 14 years
Overall probability of success
Conditional probability of success
Sources: Dimasi, Hansen, and Grabowski (2003).
Notes: The line marked “Overall probability of success” is the unconditional probability of reaching a
given stage. For example, 30 percent of drugs make it to phase I testing. The line marked
“Conditional probability of success” shows the probability of advancing to the next stage of the
process conditional on reaching a given stage. For example, the probability of advancing to Phase III
testing conditional on starting Phase II testing is 48 percent.