DS Smith to replace EPS with corrugated cardboard in cold chain logistics

UK – DS Smith unveiled a new fibre-based, temperature-controlled packaging solution, TailorTemp, at PharmaPack Europe 2025.

The solution emphasizes recyclability, a 36-hour cooling capability, and customizability through an advanced parametric algorithm.

It aims to support pharmaceutical and biotech companies in achieving their sustainability goals when storing and transporting sensitive medicinal products under controlled temperatures.

Both the outer box and insulant materials are made of corrugated cardboard, designed by DS Smith.

While the solution does not currently include reusable coolant elements like gel packs, it eliminates the need for expanded polystyrene (EPS) components, offering a 100% plastic-free and recyclable alternative.

Unlike traditional EPS boxes, which are transported fully assembled, TailorTemp is delivered in a flatpack format, reducing transportation costs and optimizing space for inbound and outbound logistics.

The pack can maintain a constant temperature of 23°C for up to 36 hours, though validation under ISTA 7D Winter and Summer profiles is still in progress.

Its dimensions, insulating thickness, and coolant specifications are determined using a computer-based parametric algorithm developed by DS Smith in collaboration with a thermal transfer laboratory.

This predictive modelling tool enables customers to tailor the pack to their specific needs, minimizing material use and waste while accounting for temperature fluctuations during storage or transit.

In one case study, DS Smith’s Circular Design Metrics tool demonstrated that a 42mm corrugated insulant achieved a 40% reduction compared to a 50mm EPS insulant.

However, the exact CO2 savings depend on the packaging specifications of individual customers.

DS Smith expects TailorTemp to help businesses comply with the upcoming Packaging and Packaging Waste Regulation and contribute to its Now and Next Sustainability Strategy.

Marlena Hardy, Innovation Product Manager at DS Smith, remarked, “TailorTemp demonstrates how versatile and reliable fibre-based material can be for maintaining temperatures in cold chain logistics while delivering a recyclable outcome for customers pursuing sustainability targets.

“Design is everything, and our predictive modelling approach ensures we create solutions that are fit for purpose and validated without delay. While we’ve achieved a critical milestone with the 36-hour cooling period, our team is already working on extending this to 96 hours and beyond.”

She added that customers increasingly demand sustainable packaging solutions, noting that EPS replacements not only offer environmental benefits but can also be cost-effective.

DS Smith is also developing new surface treatments, insulating materials, and process innovations to extend TailorTemp’s cooling capability beyond 96 hours.

Subscribe to our email newsletters that provide busy executives like you with the latest news insights and trends from Africa and the World. SUBSCRIBE HERE

Newer Post

Thumbnail for DS Smith to replace EPS with corrugated cardboard in cold chain logistics

Mexico to host Global Pact Network Connect 2025 to tackle food and plastic waste

Older Post

Thumbnail for DS Smith to replace EPS with corrugated cardboard in cold chain logistics

Zeus unveils Apollo Pallet Wrapping System to slash plastic use

Be the first to leave a comment

Leave a Reply

Your email address will not be published. Required fields are marked *

This site uses Akismet to reduce spam. Learn how your comment data is processed.