DS Smith has launched an innovative temperature-controlled packaging solution for the pharmaceutical industry.
TailorTemp® was unveiled for the first time at PharmaPack Europe 2025 in Paris earlier this week.
The solution is designed to support the sustainability targets of pharmaceutical and biotech businesses, meeting their need to store and transport delicate medicinal products across multiple territories within rigorously controlled temperature environments.
Recyclable temperature control packaging for supply chain logistics
TailorTemp® is created from corrugated cardboard-based material that is recyclable. The dimensions, insulating thickness, and coolant quantity are determined using a computer-based parametric algorithm which has been co-developed by DS Smith in partnership with an independent laboratory specialising in thermal transfers. Designers can then use the outcomes of the modelling tool to fast-track prototyping and validate solutions in real conditions.
DS Smith has been able to demonstrate that this packaging solution can stay cool for up to thirty-six hours. The DS Smith component of the TailorTemp® packaging solution, comprising an outer box and the insulant materials, is fully recyclable and 100% plastic-free, representing a sustainable alternative to Expanded Polystyrene (EPS) for the packaging needs of pharmaceutical and biotech industries.
The TailorTemp® packaging solution can be tailored to meet the requirements of each customer to provide them with an efficient solution, and the corrugated cardboard can be easily adapted to the dimensions of a product to reduce the overall size of the box, minimise the use of unnecessary materials, and prevent waste.
The DS Smith design team uses TailorTemp® predictive modelling to predict temperature rises during storage or transit with a high level of accuracy. This data facilitates the efficient design process of solutions that are fit for purpose, and which are then final tested in the laboratory.
In addition, the DS Smith R&D team is also already working on a new surface treatment, insulating materials, and process innovations for TailorTemp®, to extend its ability to maintain cool temperatures for a further ninety-six hours and above.
Innovative design
TailorTemp® packaging solutions are comprised of three simple components – the outer box and two thermal liners, which can be easily assembled into the finished pack at the end of the production line or onsite by the customer. They are designed to ensure that they can be flexibly transported to customers in a flatpack format with both inbound and outbound space optimisation benefits. In comparison, Expanded Polystyrene (EPS) boxes are typically less versatile and usually need to be transported in a constructed form.
Marlena Hardy, Innovation Product Manager, DS Smith: “TailorTemp® demonstrates just how versatile and reliable fibre-based material can be, not only to maintain temperatures in cold chain logistics, but also to deliver a recyclable outcome for customers seeking to meet sustainability targets. Design is everything, and our team is using specialist predictive modelling in the creation solutions for our pharma customers that are fit for purpose and then validating them in the laboratory without delay. We are delighted to have hit the crucial thirty-six-hour milestone for cold chain storage and transportation, but the team is already hard at work on extending this to an even longer time period, and we think we will soon be able to extend TailorTemp®’s ability to maintain cool temperatures to 96 hours and above”.
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