Cold Chain Technologies (CCT), a global leader in temperature-controlled packaging, has successfully completed a landmark project with logistics giant Kuehne + Nagel and Teva Pharmaceuticals, demonstrating the viability of ocean freight for high-value, temperature-sensitive pharmaceutical shipments.

The live test involved transporting temperature-sensitive pharmaceuticals on one of the world’s most demanding sea routes - from Germany to Australia – and validated that sea freight can offer a viable, cost-effective and more sustainable alternative to air cargo.

Despite encountering multiple logistical challenges, the shipment arrived in perfect condition. The success of the mission was attributed in large part to CCT’s Enshield, a high-performance, reusable PCM thermal blanket.

Commenting on the decision to use the hugely challenging Germany-to-Australia route for the rigorous testing process, Judineth Miranda, Sr. Dir. Key Account Management Healthcare at Kuehne + Nagel, said, “This is a long journey with significant seasonal and temperature variations, which meant that a successful test would allow us to qualify many lanes in a single study.”

Kuehne + Nagel and Teva initially relied only on traditional thermal covers to complement the active containers being used, but identified the need for additional protection against an increasing number of power outages occurring at sea in recent years. To enhance temperature stability during transit, they tested the Enshield passive thermal blanket, which demonstrated significant advantages over other available options.  

Kristian Williams, Senior Director of Sales – EMEA & APAC at Cold Chain Technologies, explained, “Traditional blankets are flawed – because once hot air gets inside, it can get trapped. Enshield is designed to keep products within 2-8 degrees C – if the temperature rises above or falls below that, the phase-change material slows down the thermal exchange to keep things balanced and consistent.”

Enshield uses leakproof Koolit Advanced gel, a form-stable PCM that never turns to liquid. It is also highly flexible, allowing it to be wrapped around the pallet for a snug fit and enhanced protection.

The vessel departed from Germany in November 2023, with an estimated journey time of about 60 days.  However, a series of unforeseen challenges extended the journey by an additional 10 days – but with no impact on the target temperature range of 2-8 degrees C.

“Pretty much everything that could go wrong did so, in terms of putting pressure on the integrity of the cargo,” confirmed Fabian Reitmeier, Project Manager Logistics Integrity at Teva Logistics.

The first challenge came with the closure of the Suez Canal due to increased risk to ocean vessels, prompting a reroute around the Cape of Good Hope and extending the journey by a week.

Secondly, there was a power outage in the Indian Ocean, which was not discovered until later due to being out of GPS range.

Finally, due to the previous delay, the ship arrived in Sydney Harbour during Australia Day, when the port was operating with only a skeleton crew, further delaying the unloading process. The cargo remained in Sydney Harbour for an additional four days in ambient temperatures approaching 40 degrees C.

Remarkably, despite these extreme conditions, the temperature inside the shipment remained stable over the entire 10-week journey, thanks to the additional support provided by Enshield.

Temperature loggers recorded two minor spikes (during the power outage and upon arrival in Australia) but still remained well within the acceptable parameters and safe to use by end patients.

“This was the most challenging run we did, but the one that performed best – and it’s clear that Enshield was crucial to this success,” confirmed Miranda.

CCT highlighted the environmental advantage of this approach, noting that one pallet of airfreight flown from France to Singapore produces five times more CO? than 22 sea freight pallets.