• Developing a system for returnable packaging solutions requires a certain set of circumstances to be viable. However, knowing these circumstances is only the first step of the journey.


• TransPak is an industry leader in returnable packaging, with multiple returnable packaging solutions implemented across the world. And Kevin is involved in the work to develop and implement these returnable packaging solutions, as well as manage existing returnable solutions within Asia.


• Through this presentation, Kevin hopes to share what it takes to get a returnable packaging solution off of the ground – based on real-world experience and challenges.


• If the circumstances are suitable for a returnable packaging solution – then development requires various different expertise working in harmony to succeed. Firstly, an engineered solution to meet the customers needs as well as the transportation environment are needed. Next, implementation requires a tailored supply chain considering various geographical and logistical factors. Lastly, monitoring of the returnable packaging solution needs diligent tracking and controlling, as well as pivoting when challenges arrive.


• Returnable packaging solutions offer great potential in terms of cost savings, material savings, and material efficiencies. But the success of the returnable packaging solution relies on understanding the challenges that may arise and overcoming them.

• Thermal Packaging Sustainability: Ben VanderPlas, Sonoco Thermosafe
• Frozen Product Considerations: Maarten Kleverlaan, Topa Institute
• Temperature Monitoring and Real-Time Monitoring: Richard Peck, Onasset Intelligence Inc. 

The ISTA Pharma Committee is committed to providing education and guidance through Technical Exchange sessions, work groups, ISTA Connect, and conferences.

Pulling together subject matter experts to design and publish guidance, these work groups focus on best demonstrated practices, regulatory requirement, and other significant industry guidelines and publications. This holistic global view ensures the best guidance from ISTA Pharma for ISTA members, and everyone involved in the pharmaceutical supply chain responsible for safe and effective delivery of pharmaceuticals to healthcare providers and patients.

This session will focus on recent activities/updates from:

• US Pharmacopeia (USP) Packaging and Distribution Expert Committee,  


•  Parenteral Drug Association (PDA),


•  Asia-Pacific Economic Cooperation (APEC),


•  International Organization for Standardization (ISO),


• International Air Transport Association (IATA),


• BioPhorum Operations Group (BPOG)

New trends in packaging research recommend ecological transition towards circular economy, encouraging use agroindustrial byproducts. In this context, a project focused on the development of innovative biodegradable materials enriched with tomato and artichoke byproducts, or obtained from residues from processing of durum wheat pasta, has been carried out.  

The multidisciplinary of the involved team was a key factor that allowed a synergy between chemists,  engineers, and designers,  facing different aspects of the entire process of packaging development.  

Cellulose-based materials and biodegradable foams were designed in terms of macro- and micro-cellular structure to provide exceptional vibration and impact protection for fragile products. Origami-inspired geometry and cellular foams were studied to evaluate vibration attenuation and impact mitigation. The dynamic properties of the structures were investigated through elastic wave propagation analysis, demonstrating that an absolute band gap can be obtained and tuned according to geometry. Foam prototypes were mechanically tested to evaluate elastic behaviour and energy absorption capabilities.  

Through an immersive workshop, the research investigated the strategic role of packaging design as both a communicative and protective device, exploring the experimental features of these emerging materials. The design activity led to the development of concepts and prototypes integrating sensoriality, aesthetic qualities, and mechanical performance, examining the formal and functional potential of materials to define innovative solutions. 

The achieved results permitted to obtain materials that can be proposed in many fields including cosmetics and jewellery. Further developments will focus on LCA, economical sustainability, and process optimisation for potential industrial production.
 
 

• Definition of why we need protective packaging


• Brief review of the present protective packaging market


• Why sustainability is a need in pack design - minimum packaging giving maximum protection


• Package testing is the key to address new innovations in protective packaging


• Non commercial review of new packaging innovation solutions in the market today and the future


• Why we need both plastic and paper packaging  innovations

The use of resources is a major challenge in every sector. The world of packaging makes no exception. In combination with cost and efficiency challenges that companies face, it makes sustainable packaging a hot topic. However, reusable packaging solutions face persistent challenges that hinder widespread adoption:

1. Complex and inefficient reverse logistics
2. Cumbersome handling
3. Higher operational costs compared to single-use alternatives

In partnership with Decathlon Switzerland, KWiiD has developed and implemented a reusable packaging solution that achieves a 97% reduction in CO2 emissions per cycle compared to disposable packaging, while also delivering cost savings at scale.

 

This session will focus on the creation and rationale behind compensating factors (F values) and how to utilize the knowledge for appropriate business use, as well as impact of those altered compression weights to testing results on corrugated materials. Additionally, special attention will be given to how the factor of humidity impacts the calculated compensating factors and what real-world situations should be considered when determining the variables for the calculation. The discussion will be centered around the risk, benefit, and strategy of utilizing custom compression calculations to fit individual business needs as well as presenting actual testing data from ISTA 3E testing using altered F values. 

Ensuring the integrity of temperature-sensitive pharmaceutical and biotech products during transit remains a critical challenge in global supply chains. Traditional reliance on physical shipment data, although valuable, often involves resource-intensive efforts and can be limited by logistical constraints. In this context, advanced simulation modeling offers a promising alternative for proactive risk assessment and decision-making.

This presentation details a recent pilot project that validates the use of sophisticated simulation models to predict ambient temperature profiles in cold chain shipments. By comparing the temperature data generated through modeling with real-world data collected from dataloggers deployed during multiple shipments, the study demonstrates a high degree of correlation, including accurate predictions of temperature peaks, cold exposures, and steady-state conditions.

Key metrics such as extreme temperature values, area under the curve (AUC), and time spent within specific temperature ranges were closely matched, confirming the reliability of the modeling approach. Additionally, the iterative refinement of models—incorporating environmental factors like sun exposure—further improved predictive accuracy.

The results underscore the potential of simulation modeling as a strategic tool for risk management, lane mapping, and process optimization in cold chain logistics. Leveraging this technology can reduce dependency on physical testing, accelerate shipping plans, and enhance product safety and compliance. Ultimately, this approach supports smarter, more resilient cold chain strategies aligned with evolving industry standards and regulatory expectations.