High-Performance Thermal Packaging Development for Pharma Shipment Integrity

Client Overview

A prominent medical group engaged Adept to identify a more cost-effective solution for transporting temperature-sensitive blood plasma. Their existing packaging system relied on a pre-qualified thermal shipper using vacuum insulated panels (VIPs) and large dry ice blocks, delivering performance but at an unsustainable cost. The client needed a custom design that would maintain product integrity while significantly lowering costs.

Adept delivered a high-performance, cost-effective thermal shipping solution that met the unique demands of blood plasma transport. The final design maintained all critical product protections while significantly lowering operational costs and providing the client with a scalable model for future temperature-sensitive shipments.

The Challenge

The client’s current shipper was reliable but over-engineered and expensive. They needed a new solution that delivered the same thermal performance while being easier to manage, more scalable, and aligned with cost-reduction goals.

  • The current pre-qualified shipper used costly vacuum insulated panels and heavy dry ice blocks

  • Packaging costs were too high to support growing distribution needs

  • Any new designs needed to maintain strict quality and regulatory performance standards

  • A custom solution was required, but internal resources lacked bandwidth to develop and validate it

  • The replacement had to meet pre-approved acceptance criteria without delays in deployment

Our Approach

Adept collaborated with the client’s operations and quality teams to fully understand the performance targets and existing shipping workflows. We engineered a custom thermal shipper with redesigned insulation and dry ice tray configurations that preserved cooling efficiency while reducing cost. The solution was rigorously tested and validated to meet all shipping and product safety requirements.

  • Worked closely with stakeholders to define thermal and handling requirements

  • Developed multiple insulation and dry ice tray configurations to optimize performance and cost

  • Conducted testing to ensure the new shipper met or exceeded the original system’s standards

  • Validated performance under real-world shipping conditions and quality criteria

  • Delivered a fully engineered, ready-to-implement thermal packaging solution

The Impact

Adept's end-to-end optimization delivered more than just higher numbers:

  • 5x cost reduction achieved through custom packaging redesign

  • Robust custom thermal shipper developed to protect temperature-sensitive plasma

  • Validated performance that maintained required cooling efficiencies and quality standards

  • Seamless integration into existing workflows without sacrificing reliability

This isn't just a fix. It’s a transformation.

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