Inside DS Smith's Cold Chain Revolution

The global cold chain logistics market is on track to expand from US$322.1bn in 2023 to an impressive US$1,262.5bn by 2032, as revealed by the latest research from Astute Analytica.

The industry’s growth reflects rising demand for temperature-controlled storage and transport across multiple sectors. However, the sector also currently contributes around 3.5% of the global carbon footprint, placing sustainability and technological innovation at the forefront of discussions about its future.

Companies are now under increasing pressure to balance environmental considerations with efficiency. Advances such as artificial intelligence and renewable materials are playing a critical role in helping the sector optimise operations while reducing its environmental impact.

DS Smith introduces fibre-based TailorTemp packaging

One standout innovation comes from DS Smith, a global leader in sustainable packaging solutions, which showcased its new fibre-based, temperature-controlled packaging, TailorTemp, at PharmaPack Europe 2025.

TailorTemp is specifically designed to support pharmaceutical and biotech firms in achieving their sustainability goals while ensuring the safe storage and transport of sensitive medicinal products in controlled conditions.

Made entirely from corrugated cardboard, the packaging is 100% recyclable and plastic-free, providing an alternative to expanded polystyrene (EPS), a material widely criticised for its environmental impact.

Unlike EPS boxes, which are typically transported in pre-assembled form, TailorTemp can be shipped flat-packed, helping customers save space and cut transport costs. Once delivered, the packaging can be assembled at the production line or on-site, ensuring efficiency from start to finish.

Reusable gel packs, which serve as coolant elements, are not currently supplied by DS Smith, although the company has hinted at further innovations.

Plans are underway to extend TailorTemp’s cooling capabilities from the current 36 hours to a remarkable 96 hours and beyond, thanks to ongoing developments in surface treatments and insulating materials.

Marlena Hardy, Innovation Product Manager at DS Smith, comments: “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.”

Marlena also points out the role of predictive modelling in developing these solutions, allowing DS Smith to tailor its designs to pharmaceutical clients’ needs and validate them efficiently through laboratory testing.

Industry shifts towards sustainable alternatives

The move towards recyclable and biodegradable packaging solutions is gaining traction across the cold chain logistics industry.

DS Smith is not alone in driving change. Back in 2023, Ranpak released its RecyCold climaliner, a paper-based thermal liner designed for cold chain shipping. Promising up to 48 hours of cooling and full recyclability, it marked an early step in reducing the reliance on EPS.

More recently, 2nd Level Global Solutions introduced Solaris, a line of recyclable, paper-based thermal pallet covers designed to protect goods from temperature fluctuations during transit.

Elsewhere, companies such as DGeo and Lifoam Industries are developing biobased additives to enhance the biodegradability of EPS packaging without introducing microplastics into the environment.

DS Smith’s TailorTemp stands out in this competitive landscape by combining recyclable materials with a practical design that addresses the inefficiencies of traditional packaging.

It aligns with the growing demand for sustainable options in pharmaceuticals, where temperature stability and environmental accountability are paramount.

As Marlena notes: “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.

"Customers are increasingly demanding sustainable and recyclable packaging solutions, so the benefit of replacing EPS with a fibre-based solution can’t be overlooked and bespoke EPS solutions can be cost prohibitive.”

TailorTemp exemplifies how innovation in sustainable materials is reshaping the logistics industry, proving that efficiency and eco-consciousness can go hand in hand.

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