Program Archive
Led by expert ISTA Instructor, Carolyn Williamson, ISTA Pharma Committee Officer.
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2026 ISTA Forum USA
Tuesday, April 7, 2026 7:30am - 12:30pm
Pre-Forum Training: ISTA CC 201 Introduction to BioPharma Cold Chain (additional fee)
ISTA CC 201: Introduction to BioPharma Cold Chain Training
The Who, What, Why, Where of Cold Chain
- Basics of a cold chain program
- Attributes of a gold standard cold chain program
- Guiding standards for the industry
- Introduction to the Shipping Qualification Process Flow
- Lessons learned on selecting test labs and suppliers (labs, packaging, recording devices, etc.)
Led by expert ISTA Instructor, Carolyn Williamson, ISTA Pharma Committee Officer.
Tuesday, April 7, 2026 7:30am - 5:00pm
Pre-Forum Training: ISTA PDP Certification (additional fee)
Get ISTA Packaging Dynamics Professional (ISTA PDP) Certified with this comprehensive in-person training. To receive ISTA’s Packaging Dynamics Professional (ISTA PDP) Certification, you must complete all six PDP courses and pass the corresponding exams. Take the ISTA PDP Certification exams conveniently online through ISTA’s learning platform—complete with full video presentations and course content to help you prepare and succeed. PDP courses included:
- PDP 101: Principles of Distribution Packaging
- PDP 201: Atmospheric & Compression Hazards in Transit
- PDP 202: Shock & Drop Hazards in Transit
- PDP 203: Vibration Hazards in Transit
- PDP 204: Test Laboratory Operations & Instrumentation
- PDP 205: Test Procedures & Enhanced Simulation Testing
Click here to view the full schedule and rates with and without Forum registration.
Led by expert ISTA Instructor Larry Dull, this in-person training is a convenient option to becoming a certified ISTA Packaging Dynamics Professional.
Tuesday, April 7, 2026 12:00pm - 4:00pm
Pre-Forum Training: ISTA CC 301 URS to OQ (additional fee)
User Requirement Specification to Operational Qualification Training
The How of Cold Chain – Taking the fundamentals of the first class and putting it into practice
- How to create a robust URS
- Highlight both major and minor attributes of a URS
- How to design and implement your OQ process
- Highlight the design qualification tests
- Execution of an OQ protocol
- Documentation
- Test Protocols and Reports
- Temperature Recording Device Settings
- Operational SOP/WIs
- Staff training
- How to select and implement a pre-qualified shipper
- Navigating Change Control to Implement your Qualified System
- Lessons Learned on Implementing a Qualified Shipping System
- Case Studies
Led by expert ISTA Instructor, Carolyn Williamson, ISTA Pharma Committee Officer.
Tuesday, April 7, 2026 4:00pm - 5:30pm
Forum Welcome Reception
Networking Hub
Join us at the ISTA Forum Networking Hub to kick off the event! Enjoy complimentary drinks and snacks while catching up with friends old and new. It’s the perfect way to start the ISTA Forum, and we look forward to welcoming you! Please note: The reception is complimentary for attendees. Guest tickets are available for purchase when registering. Attendees and guests must be 18 years old.
Tuesday, April 7, 2026 6:00pm - 8:00pm
ISTA Educational Foundation Fundraiser Dinner (additional fee)
Supporting the Next Wave of Packaging Industry Leaders! Join us for a fun evening at the ISTA Educational Foundation Dinner on Tuesday, April 7, from 6:00–8:00 PM at the Carcara Citrus Grove Patio within the Sheraton (immediately following the ISTA Forum Welcome Reception). Connect with peers, support student scholarships and research, and help empower the next generation of packaging leaders.
Click here to learn more.
Click here to learn more.
8:30am - Welcome & Meet Your Fellow Delegates
Location: Room: Valley of the Sun D/E
A.J. Gruber
ISTA
A.J. will open the TransPack sessions with key information to help you make the most of the event. This is also a great opportunity to meet and connect with fellow attendees as we kick things off together.
8:30am - Welcome & Meet Your Fellow Delegates
Location: Room: Valley of the Sun A/B
Bryan Cardis
Cold Chain Technologies
Bryan will open the TempPack sessions with key information to help you make the most of the event. This is also a great opportunity to meet and connect with fellow attendees as we kick things off together.
9:00am - 2035 Global Packaging Thought-Leader Survey
Location: Room: Valley of the Sun D/E
Brian Wagner
PTIS
Unveiling the 2025-2035 Horizon – Insights from the PTIS Future of Packaging Global Thought Leader Survey
In an era of accelerating disruption, the 2025 edition of PTIS’s triennial Future of Packaging Global Thought Leader Survey captures the collective foresight of over 150 curated experts from academia, industry associations, and Fortune 500 leaders across the global packaging value chain. This presentation distills key findings projecting transformative trends from 2025 to 2035, spotlighting the dominance of circular economy principles, regulatory pressures, and recovery infrastructure as top forces reshaping packaging strategies.
Drawing on rigorous foresight methodologies, the survey reveals escalating priorities in sustainability—where reusable, refillable, and compostable solutions outpace traditional recycling—fueled by digital innovations like IoT-enabled packaging and AI-driven supply chains. Attendees will explore actionable implications for CPG, manufacturing, and retail sectors, including risk mitigation in volatile markets, consumer-driven demands for eco-transparency, and opportunities for Horizon 3 innovations that integrate packaging into a holistic, value-creating ecosystem.
Join us to gain strategic foresight that equips your organization to navigate complexity, foster resilience, and pioneer sustainable growth in the decade ahead.
8:45am - ISTA Pharma Committee Update: Advancing The Industry Through Collaboration
Location: Room: Valley of the Sun A/B
Bryan Cardis
Cold Chain Technologies
Carolyn Williamson
Parenteral Supply Chain
Arminda Montero
AbbVie
Bill Mayer
Peli BioThermal
Anthony "TJ" Rizzo
Cold Chain Technologies
Join the ISTA Pharma Committee Officers as they provide insights into the ongoing advancements of the Pharma Committee, offer an overview of the recently developed guidance documents, and outline the committee's upcoming initiatives. The ISTA Pharma Committee is an Ad Hoc Technical Committee comprised of individuals from both supplier partners and Life science end-user organizations involved in the supply chain for temperature-sensitive products. The committee’s goal is to develop and publish peer reviewed technical guidance that addresses relevant needs of the industry as well as provide a forum for industry members to collaborate and share best practices.
9:30am - Agentic AI and the Future of Productivity in Packaging and Distribution
Location: Room: Valley of the Sun D/E
William Green
IBM Corporation
Artificial Intelligence is no longer a distant frontier—it’s a daily partner in how we work, innovate, and solve complex challenges. In this session, Bill Green will introduce you to the evolving landscape of AI, with a focus on the transformative potential of Agentic AI—a new paradigm where intelligent agents autonomously plan, execute, and adapt workflows across enterprise environments.
Drawing from IBM’s latest developments in watsonx.ai, Bill will explore how Agentic AI is reshaping digital labor, enabling packaging and logistics professionals to automate repetitive tasks, orchestrate complex decision-making, and accelerate sustainability goals. Attendees will gain insights into:
- The foundational building blocks of enterprise AI: data, models, agents, governance, and assistants.
- How Agentic AI differs from traditional automation and chatbots, offering contextual awareness, dynamic skill sequencing, and intelligent orchestration.
- Real-world use cases in supply chain
- The role of secure models in powering safe, performant, and transparent AI solutions tailored for enterprise needs.
Whether you're just beginning your AI journey or looking to scale intelligent automation across your operations, this session will provide a practical roadmap for integrating AI into your value chain.
9:15am - Whitepaper Updates: Sustainability in Temperature Controlled Packaging and Shipping Frozen Pharmaceuticals
Location: Room: Valley of the Sun A/B
Eduardo Molina
Center for Packaging and Unit Load Design - Virginia Tech
Alison Crawley
ThermoSafe
Carolyn Williamson
Parenteral Supply Chain
Guided by insights from recent industry surveys, the ISTA Pharma Committee has identified these topics as priorities for new industry guidance. This session provides an overview and progress update on two in-development ISTA Pharma Committee whitepapers: Introduction to Sustainability in Temperature-Controlled Packaging and Considerations for Shipping Frozen Pharmaceuticals. Hear directly from the whitepaper leads as they share the scope, objectives, and key focus areas of each document, offering attendees early insight into the guidance being developed.
ISTA PCW-04 | Introduction to Sustainability in Temperature-Controlled Packaging Whitepaper
Presenters:
Presenter:
ISTA PCW-04 | Introduction to Sustainability in Temperature-Controlled Packaging Whitepaper
Presenters:
- Eduardo Molina, ISTA Pharma Committee Member, Center for Packaging and Unit Load Design, Virginia Tech
- Alison Crawley, ISTA Pharma Committee Member,ThermoSafe
Presenter:
- Carolyn Williamson, ISTA Pharma Committee Vice Chair, Parenteral Supply Chain, LLC
10:30am - Characterizing the Cushioning Performance and Environmental Impact of Void Fill Packaging for E-Commerce Distributions
Location: Room: Valley of the Sun D/E
William Snyder
Toronto Metropolitan University
Achieving sustainability in protective packaging requires balancing product protection with material efficiency. In e-commerce, where parcel shipments are frequent, lightweight, and handled across multiple stages, packaging must withstand complex combinations of vibration and shock hazards while minimizing environmental impact. Over the past three decades, extensive research has focused on cushioning systems such as expanded polystyrene (EPS), evaluating their cushion curves, shock attenuation, compression strength, environmental durability, and biodegradation performance 1–9 . Sustainable alternatives have also emerged,including starch-based foams, molded pulp, and celium-based packaging, which demonstrate promising impact absorption and compressive strength comparable to EPS. However, these systems are typically custom-engineered to fit a specific product geometry, making them well-suited for standardized industrial goods but less adaptable for the diverse, irregularly shaped items shipped through e-commerce channels. In contrast, void fills offer universal applicability, they conform to varying product sizes and shapes, filling empty spaces within parcels to provide cushioning without requiring customized molds or tooling. Despite their widespread use, void fills remain one of the least characterized components of protective packaging, with limited empirical data on their cushioning efficiency, vibration damping behavior, and life cycle environmental performance. This study addresses that gap through combining laboratory testing under standardized ISTA procedures with a cradle-to-grave Life Cycle
Assessment (LCA) conducted in accordance with ISO 14040 and ISO 14044.
Assessment (LCA) conducted in accordance with ISO 14040 and ISO 14044.
10:30am - How To Set Up a Phase Appropriate Biotech Logistics Process Which is Viable, Reliable, and Robust
Location: Room: Valley of the Sun A/B
Sebastian Tomlin
Cullinan Therapeutics Inc.
Eric Elbel
Coming Soon
Early‑stage biotechnology companies face unique and rapidly evolving supply chain challenges as they progress from R&D into clinical development and, eventually, commercialization. Each phase carries distinct constraints on speed, cost, quality, and risk tolerance, requiring logistics processes that are not only technically sound but also appropriately scaled to the organization’s maturity. This presentation outlines a practical framework for designing and operationalizing a phase‑appropriate logistics model that can adapt as pipeline complexity, geographic reach, and regulatory expectations expand.
Drawing on more than 35+ years of combined experience supporting biologics, oncology therapies, cell and gene modalities, and global clinical programs, the speakers break down what “fit‑for‑phase” truly means. Topics include defining the right scope of logistics responsibilities, aligning cross‑functional stakeholders, managing increasing cold‑chain and dangerous goods requirements, and avoiding the common illusion that shipments alone represent the full extent of supply chain operations. The session further explores the progression from manual tools to integrated supply chain systems, emphasizing how early data capture and thoughtful vendor partnership strategies lay the foundation for future scalability.
Attendees will learn how to balance executional speed with procedural rigor and what steps are essential during key clinical phase transitions. The presentation concludes with actionable guidance for building resilient, right‑sized processes that remain flexible, cost‑conscious, and capable of supporting both early‑phase uncertainty and long‑term commercial readiness.
11:00am - From Oversimplified to Optimized: Setting New Benchmarks in Medical Package Testing
Location: Room: Valley of the Sun D/E
Sam Upadhyaya
Edwards Lifesciences
Ensuring the integrity and sterility of medical product packaging is a critical requirement for patient safety and regulatory compliance. This study presents an advanced framework for medical package testing designed to meet and exceed the quality and compliance requirements of recognized standards encompassing ISO 11607, ISTA 2A, 3A and ASTM D4169. While complex distribution simulation and validation protocols often receive significant attention, package drop testing—one of the critical subsets of distribution simulation testing—has historically been overlooked, oversimplified, and treated as a routine task. This work reinvigorates its role by applying precision technology and automation to elevate its scientific rigor and relevance. The methodology integrates high-precision instrumentation, automated test systems, and machine vision technologies to deliver quantitative, reproducible assessments of drop impacts. Emphasis is placed on validated, statistically robust protocols supported by real-time data acquisition and traceability systems to ensure compliance with Good Manufacturing Practices (GMP) and risk-based quality management principles. The integration of collaborative robotics and closed-loop control systems minimizes operator variability, enhances throughput, and ensures consistent distribution simulation conditioning during testing. By embracing automation with purpose, this approach does more than replace legacy tools—it reshapes the landscape of packaging science and establishes new industry benchmarks, with Edwards Lifesciences leading the way. Results demonstrate significant improvements in measurement accuracy, process efficiency, and reliability compared to conventional manual methods. This presentation underscores the role of advanced automation and digitalization in establishing a scalable, compliant, and future-ready paradigm for medical package verification testing.
11:00am - Case Study | Customer-Informed Design: Improving Sustainability, Experience, and Cost
Location: Room: Valley of the Sun A/B
Linnette Lopez
Cold Chain Technologies
Arminda Montero
AbbVie
Life science supply chains are under increasing pressure to reduce environmental impact without compromising product integrity or user experience (both the shipper and the recipient experience). This presentation explores how customer-informed design can unlock step-change improvements in curbside recyclable thermal packaging. By integrating direct feedback from clinical sites and distribution partners into the design process, we identify critical pain points—ranging from pack-out complexity and disposal challenges to hidden cost drivers.
We will demonstrate how translating these insights into engineering requirements enables the development of patent pending right-sized, curbside recyclable solutions that deliver validated thermal performance while simplifying pack-out, improving unboxing, and reducing total landed cost. Real-world case studies highlight measurable gains in sustainability (recyclability and carbon reduction), operational efficiency (labor and cube optimization), and end-user satisfaction.
Attendees will leave with a practical framework for embedding the voice of the customer into thermal packaging innovation—turning sustainability from a constraint into a competitive advantage.
We will demonstrate how translating these insights into engineering requirements enables the development of patent pending right-sized, curbside recyclable solutions that deliver validated thermal performance while simplifying pack-out, improving unboxing, and reducing total landed cost. Real-world case studies highlight measurable gains in sustainability (recyclability and carbon reduction), operational efficiency (labor and cube optimization), and end-user satisfaction.
Attendees will leave with a practical framework for embedding the voice of the customer into thermal packaging innovation—turning sustainability from a constraint into a competitive advantage.
11:30am - Statistical Characterisation of Road-Transport Vibrations for Packaging Test Design
Location: Room: Valley of the Sun D/E
Jesús Francisco Marcos
ITENE
Protective packaging is often specified conservatively because laboratory vibration tests rely on stationary, route-independent profiles that can exaggerate exposure relative to contemporary European road transport. To reduce this gap, short-time variability of road-transport vibrations was quantified from multi-axis field measurements across ten European distribution routes. Moving-RMS series were summarised as histogram-based probability density functions and fitted with three candidate distributions: three-parameter Weibull, offset Rayleigh and log-normal. Fit quality was assessed using R², mean-squared error and χ², producing route-specific severity metrics that guide the selection of packaging test levels. Across routes, one distribution consistently captured moving-RMS variability with few parameters, another excelled when tail probability was dominated by rare high-severity intervals, and a third was adequate only for narrow, near-symmetric low-severity regimes.
The fitted amplitude distributions were combined with measured PSDs to generate route-specific, non-stationary profiles that preserve spectral content and reproduce the observed short-time modulation. These models enable estimation of exceedance probabilities and route-specific severity thresholds to support risk-informed selection of vibration test levels and cushioning, with straightforward alignment to established laboratory procedures and test protocols. The outcome is more realistic laboratory excitation, improved correspondence between laboratory and field performance, and a defensible basis to avoid both unnecessary over-packaging and under-packaging without compromising product protection. Potential applications include automated analytics and reporting, route-aware test selection, predictive risk modelling, and rationalisation of protective-material variants.
The fitted amplitude distributions were combined with measured PSDs to generate route-specific, non-stationary profiles that preserve spectral content and reproduce the observed short-time modulation. These models enable estimation of exceedance probabilities and route-specific severity thresholds to support risk-informed selection of vibration test levels and cushioning, with straightforward alignment to established laboratory procedures and test protocols. The outcome is more realistic laboratory excitation, improved correspondence between laboratory and field performance, and a defensible basis to avoid both unnecessary over-packaging and under-packaging without compromising product protection. Potential applications include automated analytics and reporting, route-aware test selection, predictive risk modelling, and rationalisation of protective-material variants.
11:45am - Industry Poll on Trending Topics
Location: Room: Valley of the Sun A/B
Bryan Cardis
Cold Chain Technologies
Join an interactive session where your real-time input will shape the future priorities of the ISTA Pharma Committee, helping determine the next workgroup topics based on what matters most to the industry today.
Wednesday, April 8, 2026 12:00pm - 1:30pm
Women in ISTA Networking Lunch
Connect with like-minded women in the packaging industry. Keep an eye out for the specially reserved tables during lunch – it's the perfect opportunity to connect, collaborate, and celebrate the achievements of women in packaging.
1:30pm - Networking Trivia!
Location: Room: Valley of the Sun D/E
A.J. Gruber
ISTA
Get ready for some fun networking trivia! Who doesn't love a little friendly competition!
1:30pm - Networking Trivia!
Location: Room: Valley of the Sun A/B
Bryan Cardis
Cold Chain Technologies
Get ready for some fun networking trivia! Who doesn't love a little friendly competition!
2:00pm - Development and Evaluation of a Simplified Multi-Axis Vibration Test Apparatus
Location: Room: Valley of the Sun D/E
Ian Skinner
Rochester Institute of Technology
Luke Ross
Rochester Institute of Technology
Derek Moelbert
Rochester Institute of Technology
Joe Byrnes
Rochester Institute of Technology
The ISTA Educational Foundation selected undergraduate research proposals focused on minimizing product damage throughout distribution and optimizing resource usage through effective package design. RIT students Ian, Luke, Derek, and Joe will provide an update on their research and findings related to the following proposal:
This project aims to develop a simplified, cost-effective 2-degree-of-freedom (2DOF) vibration test apparatus that induces rotational motion while mounted on a standard vertical-only Lansmont vibration table. The system will use a pivot-spine structure with elastomeric or spring components of varying stiffness (k) to enable off-vertical axis movement. The research will assess the apparatus’s ability to simulate transport-induced motions using both field and lab evaluations.
This project aims to develop a simplified, cost-effective 2-degree-of-freedom (2DOF) vibration test apparatus that induces rotational motion while mounted on a standard vertical-only Lansmont vibration table. The system will use a pivot-spine structure with elastomeric or spring components of varying stiffness (k) to enable off-vertical axis movement. The research will assess the apparatus’s ability to simulate transport-induced motions using both field and lab evaluations.
2:00pm - Qualification Process for Temperature-Controlled Trailers Under Extreme Freezing Conditions
Location: Room: Valley of the Sun A/B
Mirta Reyes
Johnson & Johnson
This study qualified a 40-ft Freezer Container for ultra-low temperature pharmaceutical transport through Operational Qualification (OQ) and Performance Qualification (PQ) phases. The container, equipped with a redundant NMF-372-02 refrigeration system, was evaluated for its ability to maintain a set point of −45°C within an operational range of −55°C to −35°C.
OQ testing included thermal mapping under empty and full-load configurations, compressor switchover, genset transition, open-door recovery, and power failure scenarios. Results confirmed stable temperature control during normal operations, with rapid recovery after stress events. Simulated product sensors remained within range throughout, ensuring no impact on product integrity.
PQ testing involved four live shipments between Ireland and Netherlands. All interior and product-simulating sensors maintained temperatures within specification during transit. Excursions occurred only during door openings for unloading and inspection, not during shipment. Visual inspection of 300 bottles confirmed zero defects. A single deviation related to sensor ice accumulation did not affect product temperatures. Procedural updates were recommended to minimize door-open times.
Conclusion: Combined OQ and PQ results demonstrate that the Freezer Container reliably maintains ultra-low temperatures under controlled and real-world conditions, supporting its qualification for pharmaceutical distribution requiring stringent temperature control.
OQ testing included thermal mapping under empty and full-load configurations, compressor switchover, genset transition, open-door recovery, and power failure scenarios. Results confirmed stable temperature control during normal operations, with rapid recovery after stress events. Simulated product sensors remained within range throughout, ensuring no impact on product integrity.
PQ testing involved four live shipments between Ireland and Netherlands. All interior and product-simulating sensors maintained temperatures within specification during transit. Excursions occurred only during door openings for unloading and inspection, not during shipment. Visual inspection of 300 bottles confirmed zero defects. A single deviation related to sensor ice accumulation did not affect product temperatures. Procedural updates were recommended to minimize door-open times.
Conclusion: Combined OQ and PQ results demonstrate that the Freezer Container reliably maintains ultra-low temperatures under controlled and real-world conditions, supporting its qualification for pharmaceutical distribution requiring stringent temperature control.
2:20pm - Enhancing Sentiment Analysis and Deep Learning for Packaging Damage Detection in Distribution
Location: Room: Valley of the Sun D/E
Jordan D'Amario
Michigan State University
The ISTA Educational Foundation selected undergraduate research proposals focused on minimizing product damage throughout distribution and optimizing resource usage through effective package design. MSU student Jordan will provide an update on her research and findings related to the following proposal:
This project seeks to bridge the gap between consumer insights and packaging innovation. The enhanced AI framework will provide more precise identification of packaging failure points related to distribution, a deeper understanding of consumer interactions with packaging, a refined sentiment analysis model capable of detecting nuanced consumer emotions, and a scalable AI approach that integrates text and image-based data for a holistic evaluation of packaging performance. The project builds upon the 2024 Forum presentation but introduces significant advancements. While the earlier work focused primarily on sentiment analysis of Amazon reviews to highlight packaging issues, this new phase incorporates deep learning for image-based damage detection and emotion-aware sentiment analysis. These enhancements will allow for a more robust, multi-dimensional evaluation of packaging performance during distribution, using both text and image data from consumer feedback.
This project seeks to bridge the gap between consumer insights and packaging innovation. The enhanced AI framework will provide more precise identification of packaging failure points related to distribution, a deeper understanding of consumer interactions with packaging, a refined sentiment analysis model capable of detecting nuanced consumer emotions, and a scalable AI approach that integrates text and image-based data for a holistic evaluation of packaging performance. The project builds upon the 2024 Forum presentation but introduces significant advancements. While the earlier work focused primarily on sentiment analysis of Amazon reviews to highlight packaging issues, this new phase incorporates deep learning for image-based damage detection and emotion-aware sentiment analysis. These enhancements will allow for a more robust, multi-dimensional evaluation of packaging performance during distribution, using both text and image data from consumer feedback.
2:30pm - Developing and Evaluating Ambient Temperature Profiles Using Real-World Shipping Lane Data
Location: Room: Valley of the Sun A/B
Samuel Skran
Thermosafe
Derek Russell
UPS
Reliable Ambient Temperature Profiles (ATPs) are critical for qualifying cold chain packaging systems under realistic conditions. In this study, we developed multiple ATPs using temperature data collected from nine distinct shipping lanes representing diverse geographic and seasonal variability. Following ISTA PCG-04 Best Practice Guidelines, profiles were constructed using statistical approaches such as the empirical rule and area-under-the-curve (AUC) methodology. These newly derived ATPs were benchmarked against industry standards and existing UPS ATPs to assess alignment and identify potential gaps. Comparative analysis highlights whether current ATPs require updates and demonstrates how data-driven ATP development can enhance confidence in packaging qualification, reduce risk of temperature excursions, and improve regulatory compliance. This work underscores the importance of leveraging real-world lane data to refine qualification protocols and optimize thermal packaging performance.
2:40pm - Evaluating Sustainable Materials for Transport of Live Ornamental Fish in Insulated Shipping Containers
Location: Room: Valley of the Sun D/E
Payton Moore
University of Florida
Gloria Mai
University of Florida
The ISTA Educational Foundation selected undergraduate research proposals focused on minimizing product damage throughout distribution and optimizing resource usage through effective package design. University of Florida students Payton and Gloria will provide an update on their research and findings related to the following proposal:
This project addresses the need to identify potential sustainable alternatives to expanded polystyrene foam (EPS) insulated containers used for shipping live ornamental fish. Florida’s ornamental aquaculture industry, the largest in the nation with $172 million in sales in 2021, relies heavily on EPS for its insulation and structural stability. However, increasing legislative restrictions on EPS due to environmental concerns, coupled with fluctuating availability and rising costs, could pose a significant challenge to ornamental fish producers. This project evaluates the performance of alternative packaging materials using mechanical and thermal tests. This introductory project aims to generate key results to help the long-term resilience of Florida’s ornamental aquaculture industry in an evolving regulatory landscape.
This project addresses the need to identify potential sustainable alternatives to expanded polystyrene foam (EPS) insulated containers used for shipping live ornamental fish. Florida’s ornamental aquaculture industry, the largest in the nation with $172 million in sales in 2021, relies heavily on EPS for its insulation and structural stability. However, increasing legislative restrictions on EPS due to environmental concerns, coupled with fluctuating availability and rising costs, could pose a significant challenge to ornamental fish producers. This project evaluates the performance of alternative packaging materials using mechanical and thermal tests. This introductory project aims to generate key results to help the long-term resilience of Florida’s ornamental aquaculture industry in an evolving regulatory landscape.
3:30pm - Full Warehouse Automation at Walmart: Transforming Packaging for an Automated Future
Location: Room: Valley of the Sun D/E
Jim Thomson
Walmart
Walmart’s scale and omnichannel strategy demand a supply chain that is faster, smarter, and more resilient. To meet these expectations, Walmart is deploying automation across its next-generation distribution centers, leveraging advanced systems from Symbotic, Knapp, Witron, and proprietary Walmart Automation technologies. These facilities integrate robotics, automated storage and retrieval systems (AS/RS), and AI-driven orchestration to handle millions of cases with unprecedented precision and throughput.
This presentation will explore how automation—from receiving and storage to picking, palletizing, and outbound—reshapes packaging requirements and industry standards. Automation introduces new dynamics that packaging engineers must address: tighter dimensional tolerances for robotic gripping, reinforced corrugate strength for high-speed conveyance, and standardized labeling for machine vision systems. Packaging that once accommodated manual handling must now withstand automated sequencing, and rapid sortation without compromising product integrity.
Key discussion points include:
• Automation Architecture: How Walmart’s automated ecosystem creates a seamless, high-throughput environment that reduces dwell time and labor dependency.
• Packaging Implications: Why automation demands precise carton dimensions, consistent case weights, and ISTA protocol updates to mitigate risks such as robotic clamp pressure and automated drop hazards.
• Industry Ripple Effect: The cascading impact on suppliers, testing laboratories, and packaging material innovation as automation becomes foundational to retail logistics.
Attendees will gain insight into Walmart’s automation roadmap and collaborative opportunities to develop packaging solutions that thrive in an automated supply chain. By aligning packaging design with automation capabilities, the industry can unlock efficiencies that benefit retailers, manufacturers, and consumers alike.
3:30pm - The Impact of Refrigerant Geometry and Combination on the Thermal Performance of ISCs
Location: Room: Valley of the Sun A/B
William Pelletier
University of Florida
Lucas Avery
Illuminate
The size and configuration of refrigerants play a critical role in determining the thermal performance of insulated thermal shippers (ISCs). While total refrigerant mass (ice packs, PCMs, etc.) defines the ISC’s potential to absorb or release thermal energy based on the environment temperature, the surface area-to-volume ratio influences the rate of heat transfer and its phase change. Because of differences in total exposed surface area, a combination of smaller ice packs may melt more rapidly and deliver faster initial cool in but may also lead to shorter temperature hold times than a single large refrigerant pack with the same total mass.
The presence of air gaps, variable placement, and uneven surface contact alters heat transfer pathways and can result in non-uniform temperature distribution within the packaging system. Therefore, optimizing cold-chain performance requires consideration not only the total refrigerant mass but also pack size, geometry, and spatial distribution inside the container. The results of thermal experiments studying these factors will be presented.
The presence of air gaps, variable placement, and uneven surface contact alters heat transfer pathways and can result in non-uniform temperature distribution within the packaging system. Therefore, optimizing cold-chain performance requires consideration not only the total refrigerant mass but also pack size, geometry, and spatial distribution inside the container. The results of thermal experiments studying these factors will be presented.
4:00pm - Live Benchmarking: Packaging Insights
Location: Room: Valley of the Sun D/E
A.J. Gruber
ISTA
Join us for an interactive benchmarking session featuring live polling to gain real-time insights into best practices, sustainability strategies, damage rates, emerging trends, and the role of technology in optimizing packaging solutions. Compare your approach with industry peers and discover ways to drive smarter, more sustainable packaging decisions.
4:00pm - End User Panel: Manufacturer to Patient | Navigating the Next Era of Temperature-Sensitive Pharmaceutical Supply Chains
Location: Room: Valley of the Sun A/B
TBD TBD
TBD
As temperature-sensitive therapies, biologics, and specialty drugs continue to reshape the pharmaceutical landscape, the journey from manufacturer to patient has never been more complex—or more critical. This expert panel brings together leaders from manufacturing, distribution, and specialty pharmacy to examine today’s biggest cold-chain challenges and the operational, technological, and risk-management shifts that will define the next era of pharmaceutical supply chains.
Wednesday, April 8, 2026 5:30pm - 7:30pm
Forum Sponsor Exhibition Reception
Networking Hub
Relax and enjoy hors d'oeuvres and drinks as you network and learn about the Forum Sponsors products, services, and innovative solutions. This reception is always a great time and even includes a chance to win a raffle prize! Please note: The reception is complimentary for attendees. Guest tickets are available for purchase when registering. Attendees and guests must be 18 years old.
8:30am - Amazon Packaging: ISTA Testing as the Foundation of Customer Promise
Location: Room: Valley of the Sun D/E
Paul Larson
Amazon
This presentation explores how Amazon uses ISTA—the global gold standard for packaging testing—as a foundation for delivering exceptional customer experiences in e-commerce packaging. Over fifteen years, the evolution from initial innovations to today's global standards demonstrates how scientific testing protocols enable Amazon to make and keep promises to customers. The journey encompasses frustration-free packaging, products shipping in original containers, and specialized approaches for premium heavy and bulky items. Standardized ISTA testing protocols create a reinforcing cycle: protecting products, reducing waste, building customer confidence, and driving industry-wide improvements. Effective packaging success is measured not merely by protection, but by the confidence to promise customers their products will arrive exactly as expected, every single time.
8:30am - Pharma Industry Update
Location: Room: Valley of the Sun A/B
Chris Anderson
Cardinal Health
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:
This session will focus on recent activities/updates from:
- Pharma Growth update
- 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),
- Healthcare Distribution Alliance (HDA).
9:00am - Draft Test Blocks for Drop Testing from Field Data: Profile Generation and Verification
Location: Room: Valley of the Sun D/E
Elin Akerlund
RISE Research Institutes of Sweden AB
Prashanth Srinivasa
RISE Research Institutes of Sweden AB
The aim of transport testing in the laboratory is to help design and evaluate the packaging. For this, the test protocol has to be representative of conditions encountered during transport and be able to reproduce the damages. This study will present the results of the analyses of field data of drop/shock collected from decoy packages transported in USA and China.
The aim of the study has been threefold: (a) review of the existing reduction techniques for converting shock/drop data into laboratory test protocols, (b) propose a suitable workflow for translating field data into laboratory test protocols, (c) verify the proposed new test protocols against existing protocols and where possible against the field data.
To this end, we first evaluate the field data based on the existing ISTA data analysis guidelines (based on Sheehan’s method). We conclude that this results in rather harsh test profiles that is not representative of real world conditions. We propose modifications and generate profiles which could better represent the field data. These profiles are then verified in the laboratory setting using decoy packaging similar to the ones used during field data collection. This is done partly by comparing the damage incurred by the packages when tested with the generated profiles (including ISTA 3A), and partly by comparing the damage observed in the laboratory to that in the field. The damage evaluation utilises RISE damage coefficient method that provides a somewhat objective means of comparing the damage incurred during testing of the different profiles.
The aim of the study has been threefold: (a) review of the existing reduction techniques for converting shock/drop data into laboratory test protocols, (b) propose a suitable workflow for translating field data into laboratory test protocols, (c) verify the proposed new test protocols against existing protocols and where possible against the field data.
To this end, we first evaluate the field data based on the existing ISTA data analysis guidelines (based on Sheehan’s method). We conclude that this results in rather harsh test profiles that is not representative of real world conditions. We propose modifications and generate profiles which could better represent the field data. These profiles are then verified in the laboratory setting using decoy packaging similar to the ones used during field data collection. This is done partly by comparing the damage incurred by the packages when tested with the generated profiles (including ISTA 3A), and partly by comparing the damage observed in the laboratory to that in the field. The damage evaluation utilises RISE damage coefficient method that provides a somewhat objective means of comparing the damage incurred during testing of the different profiles.
9:00am - Pharma Waste and How Our Digital Strategy Can Support a Reduction
Location: Room: Valley of the Sun A/B
Tiffany Paupst
Merck
This presentation examines how pharmaceutical logistics can simultaneously reduce waste, emissions, and cost while safeguarding access to innovative therapies. It situates cold chain challenges within broader mega-trends such as climate change, demographic shifts, new therapy modalities, and increasing healthcare budget pressure, and uses the scale of global product and packaging waste to frame sustainability as a core affordability issue. The case study describes how a digital, end-to-end logistics program, integrating internal and external data for real-time visibility, alerts, and interventions, can significantly reduce avoidable waste across international, domestic, and last-meter flows. The talk further outlines complementary enablers, including optimized transport mode selection with CO2 lane comparison, advanced thermal protection systems that support reuse and recycling, and product-level technologies such as smart labels, serialization, and product density metrics. Together, these elements are presented as a practical roadmap to drive behavior change, strengthen supply chain resilience, and deliver measurable improvements in cold chain sustainability.
9:30am - The Ocean Container Journey
Location: Room: Valley of the Sun D/E
Miguel Herrera
Allianz Commercial
Containerized cargo losses at sea often originate well before a vessel departs—driven by preventable breakdowns in documentation, packing/stuffing, weight verification, stowage planning, and securement. This session follows the end-to-end container transit lifecycle (pre-transit, transit, post-transit) to help shippers, forwarders, carriers, terminals, and insurers identify where risk is introduced and how it can be controlled. Attendees will review the principal onboard loss drivers across four categories: physical damage (e.g., misdeclared weights, improper lashing, vessel motion, poor stowage decisions), environmental exposure (saltwater, condensation, humidity, temperature extremes, contamination, loss overboard), fire (misdeclared/undeclared dangerous goods, lithium-ion battery events, containment challenges), and theft/security (port/terminal theft, inland/drayage theft, seal tampering, and cyber intrusion).
9:30am - From Home to Lab: Shipping Diagnostic Specimens Through the Transport Environment
Location: Room: Valley of the Sun A/B
Shyam Saladi
Neelyx Labs
James Parkin
Neelyx Labs
Diagnostic testing is moving into the home. Driven by post-pandemic consumer expectations, evolving commercial and reimbursement frameworks, and the reality that greater access drives improved outcomes, home-collected specimens like fingerstick blood or a urine sample represent a growing segment of the clinical laboratory market. In this model, a patient receives a collection kit, collects their specimen at home, and ships it to a centralized laboratory. This is particularly impactful for conditions like HIV, STIs, diabetes, and kidney disease, where stigma or inconvenience depress screening rates.
For the packaging community, this trend introduces a new application: shipping a perishable, biologically active payload, packaged by the patient rather than a trained operator, through ambient courier networks. Diagnostic specimens are inherently dynamic—temperature excursions during transit can drive analyte degradation, intracellular-extracellular exchange, hemolysis, and other issues, all compromising the fidelity of the laboratory result to the patient's true physiological state at the time of collection.
The diagnostics field has responded with a range of strategies: dried specimen formats that are inherently more temperature-resistant, engineered shippers with phase-change materials or battery-powered temperature control, and laboratory approaches that account for ambient transport and address specimen changes analytically post-hoc. Each carries tradeoffs in cost, analyte menu, and diagnostic performance. This talk examines how to characterize the thermal profiles specimens actually experience, map those profiles to analyte stability endpoints, and derive design criteria—motivating the use of ISTA thermal conditioning profiles for validating home-collection diagnostics end-to-end.
For the packaging community, this trend introduces a new application: shipping a perishable, biologically active payload, packaged by the patient rather than a trained operator, through ambient courier networks. Diagnostic specimens are inherently dynamic—temperature excursions during transit can drive analyte degradation, intracellular-extracellular exchange, hemolysis, and other issues, all compromising the fidelity of the laboratory result to the patient's true physiological state at the time of collection.
The diagnostics field has responded with a range of strategies: dried specimen formats that are inherently more temperature-resistant, engineered shippers with phase-change materials or battery-powered temperature control, and laboratory approaches that account for ambient transport and address specimen changes analytically post-hoc. Each carries tradeoffs in cost, analyte menu, and diagnostic performance. This talk examines how to characterize the thermal profiles specimens actually experience, map those profiles to analyte stability endpoints, and derive design criteria—motivating the use of ISTA thermal conditioning profiles for validating home-collection diagnostics end-to-end.
10:30am - Google's Open Source Random Vibration Test of Off-the-Shelf Data Center Hardware Project
Location: Room: Valley of the Sun D/E
Ken Leung
Google Inc.
The rise of AI has brought significant complexity and miniaturization to data center hardware. Components in servers and switches are now smaller, denser, and structurally more intricate. As cloud services and AI become central to everyday life, hardware failures due to shock and vibration can have real-world consequences.
AI is also expanding into fields like edge computing, autonomous vehicles, and robotics. Hardware designed for data centers may soon power these technologies, making shock and vibration testing critical to their long-term reliability.
For more than 7 years, Google Cloud has been investigating real world random vibration conditions, trying to come up with the most accurate random vibration profiles for shock and vibration testing of Google's data center hardware, and the best way to understand their failure modes. This work was released as a part of Google's Open Source Random Vibration Test of Off-the-Shelf Data Center Hardware project, which includes:
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Google's world wide field data measurement, analysis, and lab replication methods
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State of the art 3D strain, motion, deformation, and pressure measurement techniques for data center hardware
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High-speed microscopic motion analysis of critical microelectronics components
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Margins and fatigue analysis in the context of global transport and handling
This project was launched at the 2024 OCP Global Summit, and shared through the project's GitHub repository. The project aims to encourage future collaboration and make random vibration testing universally accessible and useful to the broader community.
10:30am - Empowering the Next Generation: ISTA Pharma Committee's Educational Outreach
Location: Room: Valley of the Sun A/B
Mary Alvarez Valverde
University of Wisconsin-Stout
Brian Wallin
Cold Chain Technologies
Grace Bilicki
University of Wisconsin-Stout
Tate Lidberg
University of Wisconsin-Stout
The ISTA Pharma Committee is committed to advancing education within the Life Sciences industry by building bridges between academic institutions and professional sectors. Recognizing the growing importance of temperature-sensitive logistics in pharmaceutical development and distribution, the Committee is launching initiatives designed to spark interest, foster knowledge-sharing, and establish clear career pathways for students and emerging professionals.
Through strategic partnerships, targeted educational outreach, and industry-focused programs, the ISTA Pharma Committee aims to raise awareness, generate excitement, and support the next generation of talent for Cold Chain professions within the Life Sciences industry. These efforts are essential to meeting the growing demand for skilled professionals in this critical area of pharmaceutical logistics.
Through strategic partnerships, targeted educational outreach, and industry-focused programs, the ISTA Pharma Committee aims to raise awareness, generate excitement, and support the next generation of talent for Cold Chain professions within the Life Sciences industry. These efforts are essential to meeting the growing demand for skilled professionals in this critical area of pharmaceutical logistics.
11:00am - The Convergence of Sustainability Targets and Regulations: How Packaging Must Evolve
Location: Room: Valley of the Sun D/E
James Raw
Smithers
Various regions around the world and individual states are implementing new guidance and regulations around packaging sustainability. Drawing from the perspectives of retailers, brand owners, and packaging companies, this presentation will explore several key regulations, such as the EU Packaging and Packaging Waste Directive (PPWD), extended producer responsibility (EPR) obligations, and post-consumer recycled (PCR) content initiatives. The discussion will also review how these changes are affecting the supply chain and testing requirements for a wide variety of packaging applications.
11:00am - Improving Thermal Stability of Commodity Plastics For Pharmaceutical Packaging To Mitigate Heat-Induced Degradation
Location: Room: Valley of the Sun A/B
Hethson Mwinkum
Michigan State University
Stephanie Ihejirika
Michigan State University
Background
Heat-induced degradation of polymeric packaging materials can lead to the formation of leachable, posing risks to the safety and stability of packaged products. This study aims to mitigate thermal degradation by incorporating suitable additives into common packaging polymers used in the pharmaceutical industry: HDPE, LDPE, and PP. The additives were selected to modify the polymers’ melting and degradation, thereby reducing leaching potential during product processing and storage.
Methods
DSC was used to evaluate thermal transitions specifically the onset, peak melting temperatures, and enthalpy of fusion to assess the influence of additives on the polymers' crystallinity and stability. TGA will subsequently be conducted under oxygen and nitrogen atmospheres to examine the thermal stability and decomposition of the modified materials.
Results
Preliminary DSC results revealed enhanced thermal properties across all modified polymers. Modified HDPE exhibited onset temperatures of 125-128 °C and peak melting temperatures of 138-139 °C, with enthalpy values of 195-215 J/g, indicating improved crystalline stability. LDPE with additives samples displayed onset around 115-116 °C and peak melting between 120-125 °C, with enthalpy ranging from 105-125 J/g. PP and its additive-modified forms exhibited higher onset (140-152 °C) and peak melting temperatures (160-165°C), indicating greater structural order and heat resistance.
Discussion
These results demonstrate that additive incorporation effectively enhances polymer thermal resilience, suggesting a viable strategy for mitigating heat-induced extractables formation. Ongoing TGA analysis will provide complementary insight into the materials’ degradation and oxidative stability.
Heat-induced degradation of polymeric packaging materials can lead to the formation of leachable, posing risks to the safety and stability of packaged products. This study aims to mitigate thermal degradation by incorporating suitable additives into common packaging polymers used in the pharmaceutical industry: HDPE, LDPE, and PP. The additives were selected to modify the polymers’ melting and degradation, thereby reducing leaching potential during product processing and storage.
Methods
DSC was used to evaluate thermal transitions specifically the onset, peak melting temperatures, and enthalpy of fusion to assess the influence of additives on the polymers' crystallinity and stability. TGA will subsequently be conducted under oxygen and nitrogen atmospheres to examine the thermal stability and decomposition of the modified materials.
Results
Preliminary DSC results revealed enhanced thermal properties across all modified polymers. Modified HDPE exhibited onset temperatures of 125-128 °C and peak melting temperatures of 138-139 °C, with enthalpy values of 195-215 J/g, indicating improved crystalline stability. LDPE with additives samples displayed onset around 115-116 °C and peak melting between 120-125 °C, with enthalpy ranging from 105-125 J/g. PP and its additive-modified forms exhibited higher onset (140-152 °C) and peak melting temperatures (160-165°C), indicating greater structural order and heat resistance.
Discussion
These results demonstrate that additive incorporation effectively enhances polymer thermal resilience, suggesting a viable strategy for mitigating heat-induced extractables formation. Ongoing TGA analysis will provide complementary insight into the materials’ degradation and oxidative stability.
11:30am - Latest Updates on ISTA Digital and Education
Location: Room: Valley of the Sun D/E
Matt Thompson
ISTA
Explore the latest enhancements to ISTA’s digital cloud platform, including improved distribution mapping and the launch of ISTA Connect—a new collaboration tool for real-time project sharing. Matt will also share updates on ISTA’s expanded education programs, including PDP certification, Cold Chain Packaging (CC 101), and new Test Procedure Training courses. A schedule of upcoming live virtual training events will also be shared.
11:40am - Building Transit Hazard Knowledge Through Research
Location: Room: Valley of the Sun D/E
Brian O'Banion
ISTA
Research remains at the forefront of ISTA’s efforts to continue delivering current, and relevant tools the packaging industry can use to design effective packaged-product systems for transit.
Updates will be provided on ISTA’s research to establish a standard methodology to generate draft test blocks for shock and vibration from field data, as well as research conducted through the ISTA Advocate Research & Value Delivery Program and ISTA-funded research grants.
Gain insights on all the new resources ISTA is developing that will help you and your company design effective packaging that minimizes product damage and optimizes resource usage.
Updates will be provided on ISTA’s research to establish a standard methodology to generate draft test blocks for shock and vibration from field data, as well as research conducted through the ISTA Advocate Research & Value Delivery Program and ISTA-funded research grants.
Gain insights on all the new resources ISTA is developing that will help you and your company design effective packaging that minimizes product damage and optimizes resource usage.
11:50am - Advancing ISTA Standards: Protocol Updates and Emerging Test Innovations
Location: Room: Valley of the Sun D/E
Eric Hiser
ISTA
Discover the latest developments shaping ISTA’s testing landscape. This session will cover significant protocol updates, including a revised 3E compression formula, enhanced flexibility for executing 3H, and improvements to retailer-specific tests such as 6-Sam’s, 6-Amazon.com-Over Boxing, and 6-Amazon.com-SIOC. We’ll also introduce new test initiatives designed to meet global distribution challenges—covering inbound e-fulfillment, regional protocols for Europe and India, and advanced approaches for window & appliance shipments. Gain insights into how these changes and innovations will help your organization design resilient, efficient packaging solutions for today’s dynamic distribution environments.
11:30am - Cold Chain Visibility as a Strategic Asset: From Control Towers to Confident Release Decisions
Location: Room: Valley of the Sun A/B
Jeff Lander
Moderna
As pharmaceutical supply chains become more global and temperature-sensitive, visibility is no longer optional.. it is foundational. This presentation provides a practical introduction to getting started with end-to-end supply chain visibility for cold chain logistics. Attendees will learn how a global logistics control tower serves as the backbone for real-time shipment monitoring, exception management, and data-driven decision making. The session will also cover how temperature release strategies can be enabled through integrated data, risk assessment, and quality alignment, reducing delays and product loss. Designed for pharmaceutical companies at any stage of maturity, this presentation offers a clear roadmap from foundational visibility to operational excellence in cold chain logistics.
1:30pm - ISTA Educational Foundation Awards Presentation
Location: Room: Valley of the Sun D/E
A.J. Gruber
ISTA
We’re proud to honor individuals who have made outstanding contributions to the transport packaging industry. Three prestigious awards will recognize achievements that inspire and educate others, driving progress and improving our world through transport packaging.
- R. David Lebutt Award
- Emerging Leader Award
- Outstanding Student Award
1:30pm - Thermal Modeling of Cold-Chain Systems: Accelerating Design and Reducing Testing Burden
Location: Room: Valley of the Sun A/B
Salih Yildiz
Edwards Lifesciences
Maintaining thermal stability during global cold-chain distribution is essential to ensure the safety and performance of temperature-sensitive medical devices. In this study, a combined experimental–computational approach was developed to evaluate and optimize packaging systems for extreme environmental conditions. Transient heat transfer models were established to represent palletized configurations and validated against chamber studies performed under cold, hot, and UV exposure. Model predictions showed strong agreement with experimental measurements (>95%), confirming the reliability of the computational framework.
Historical temperature profiles from diverse shipping lanes were incorporated into the simulations, enabling virtual testing of more than 20 pallet configurations under realistic transport conditions. This digital approach allowed benchmarking of insulation strategies and facilitated rapid design iterations without reliance on extensive physical testing. The optimized solution, involving the use of thermal covers and refined distribution routes, has already yielded substantial cost savings and is projected to deliver more annually.
This work highlights how computational modeling can accelerate decision-making, reduce experimental burden, and provide confidence in product performance across extreme global shipping scenarios. The established workflow serves as a scalable platform for future cold-chain initiatives and demonstrates the broader potential of digital modeling in advancing sustainable and cost-effective packaging solutions.
Historical temperature profiles from diverse shipping lanes were incorporated into the simulations, enabling virtual testing of more than 20 pallet configurations under realistic transport conditions. This digital approach allowed benchmarking of insulation strategies and facilitated rapid design iterations without reliance on extensive physical testing. The optimized solution, involving the use of thermal covers and refined distribution routes, has already yielded substantial cost savings and is projected to deliver more annually.
This work highlights how computational modeling can accelerate decision-making, reduce experimental burden, and provide confidence in product performance across extreme global shipping scenarios. The established workflow serves as a scalable platform for future cold-chain initiatives and demonstrates the broader potential of digital modeling in advancing sustainable and cost-effective packaging solutions.
2:00pm - When Reuse Becomes Sustainable: Finding the Environmental Breakeven Point in Produce Distribution Packaging
Location: Room: Valley of the Sun D/E
Jay Singh
California Polytechnic State University
Mary Ellen O'Toole
Trayak, Inc.
As the packaging industry moves toward more circular systems, companies face a key question: When does reusable packaging actually become more sustainable than single-use alternatives? This study addresses that question by identifying the environmental breakeven point for reusable plastic containers (RPCs) compared to single-use corrugated packaging used in fresh produce distribution.
Using life cycle assessment (LCA) tools aligned with ISO 14040 standards and the EcoImpact-COMPASS platform, the research evaluates packaging systems across their entire lifespan, from raw material production and manufacturing to transport, washing, return logistics and end-of-life. The analysis captures multiple impact categories, including energy use, greenhouse gas emissions, water consumption, and material resource demand.
The results reveal that the environmental performance of reusable systems depends heavily on operational factors such as the number of reuse cycles, return logistics efficiency, washing energy, and regional recycling infrastructure. By identifying where and when RPCs reach their breakeven point, the study provides a practical decision framework for companies considering reusable packaging programs.
These findings help stakeholders make informed, data-driven choices that balance sustainability goals with cost and supply chain efficiency ensuring that reusable systems deliver measurable environmental benefits without adding unnecessary complexity or burden.
Using life cycle assessment (LCA) tools aligned with ISO 14040 standards and the EcoImpact-COMPASS platform, the research evaluates packaging systems across their entire lifespan, from raw material production and manufacturing to transport, washing, return logistics and end-of-life. The analysis captures multiple impact categories, including energy use, greenhouse gas emissions, water consumption, and material resource demand.
The results reveal that the environmental performance of reusable systems depends heavily on operational factors such as the number of reuse cycles, return logistics efficiency, washing energy, and regional recycling infrastructure. By identifying where and when RPCs reach their breakeven point, the study provides a practical decision framework for companies considering reusable packaging programs.
These findings help stakeholders make informed, data-driven choices that balance sustainability goals with cost and supply chain efficiency ensuring that reusable systems deliver measurable environmental benefits without adding unnecessary complexity or burden.
2:00pm - Live Industry Polling and Interactive Discussion
Location: Room: Valley of the Sun A/B
Anthony "TJ" Rizzo
Cold Chain Technologies
Building on the highest-voted trending topics, this interactive session dives deeper using live polling and small-group discussions to refine key challenges, uncover practical insights, and shape the focus of upcoming ISTA Pharma workgroups. Attendees will have the opportunity to engage directly with industry peers, asking pertinent questions and sharing perspectives in real time.
2:50pm - The Bernard McGarvey Award Presentation
Location: Room: Valley of the Sun A/B
Bryan Cardis
Cold Chain Technologies
The Bernard McGarvey Award will be presented to honor the legacy of the late Bernard McGarvey. The award recognizes individuals who have made exceptional contributions in educating those involved in the supply chain for temperature-sensitive pharma and life-science products, on minimizing transit damage and optimizing resources through effective package design.
2:30pm - Improving Unit Load Stability with Acceleration Sled Testing: A Case Study
Location: Room: Valley of the Sun D/E
Dave Leinberger
ABF Freight
Luke Venechuk
ABF Freight
Shipping products without damage in the less-than-truckload (LTL) environment can be challenging. This is especially true when shipping tall, unstable products unitized only by stretch film and a pallet. When a large manufacturer contacted ABF’s Packaging department looking to upgrade their flatbed freight to suit LTL shipping, a plan was made to meet at Virginia Tech’s Center for Packaging and Unit Load Design and test using their new pallet acceleration sled. This case study shares the testing used to validate in-transit unit load stability, improvements that were made to the packaging, as well as the capabilities and limitations of the test equipment.
3:30pm - Field Vibration Data to Accelerated Test Profile Framework
Location: Room: Valley of the Sun D/E
Changfeng Ge
RIT - Packaging Science Program
This presentation segments truck vibration data into shock-only events and random vibration, to address brittle failure caused by instantaneous shock and fatigue damage caused by random vibration. Shock data is used to compute a Shock Response Spectrum (SRS) and synthesize a corresponding acceleration-time history for lab equipment to produce shock input. The remaining vibration data is stitched to produce a Power Spectral Density (PSD) and a Fatigue Damage Spectrum (FDS) for accelerated vibration test.
3:30pm - Temperature Lane Mapping, Qualification, and Management: ISTA and USP Guidance and Case Study
Location: Room: Valley of the Sun A/B
Chris Anderson
Cardinal Health
Very little guidance has been published on Temperature Lane Mapping, Qualification, and Management. The ISTA Pharma Committee published ISTA Pharma Committee Whitepaper: Lane Management in 2023 and the United States Pharmacopeia (USP) published a draft General Chapter USP <1079.5> Transport Lane Temperature Mapping and Qualification and the peer reviewed article, “Transportation Lane Temperature Mapping and Qualification: Risk Identification and Evaluation” Pharmacopeial Forum on 1 September 2025. The final chapter will be published and effective in 2026.
The complexity of temperature lane mapping, qualification, and management is dramatically increased for wholesale distributors shipping thousands of products on hundreds of lanes. Additionally, there are additional challenges when manufacturers are evaluating freight forwarders.
This presentation will review the recently published USP general chapter and peer reviewed article to cover the USP proposed guidance. This presentation will also cover a case study of a wholesale drug distributor in the United States and a medical device distributor in Canada. The presentation will cover how lanes from multiple distribution centers were chosen out of hundreds of lanes and thousands of customer designation addresses. The presentation will cover data ingestion into Tableau Dashboards, use of risk management criteria, and evaluation against all lane data to establish a rationale to match worst-case mapped lane data and group lanes not mapped with executed lanes. Quality plans to address risks and to identify additional lanes that need to be mapped.
The complexity of temperature lane mapping, qualification, and management is dramatically increased for wholesale distributors shipping thousands of products on hundreds of lanes. Additionally, there are additional challenges when manufacturers are evaluating freight forwarders.
This presentation will review the recently published USP general chapter and peer reviewed article to cover the USP proposed guidance. This presentation will also cover a case study of a wholesale drug distributor in the United States and a medical device distributor in Canada. The presentation will cover how lanes from multiple distribution centers were chosen out of hundreds of lanes and thousands of customer designation addresses. The presentation will cover data ingestion into Tableau Dashboards, use of risk management criteria, and evaluation against all lane data to establish a rationale to match worst-case mapped lane data and group lanes not mapped with executed lanes. Quality plans to address risks and to identify additional lanes that need to be mapped.
4:00pm - Prediction Modeling of Pallet Overhang on Box Compression Strength
Location: Room: Valley of the Sun D/E
Eduardo Molina
Center for Packaging and Unit Load Design - Virginia Tech
Accurate prediction of box compression strength (BCT) loss resulting from pallet overhang is critical for maintaining the integrity of corrugated packaging in global logistics. This study presents an expanded empirical analysis and predictive modeling framework to quantify the impact of pallet overhang on BCT. An integrated dataset that combined data from previous research with newly conducted experiments was developed to capture a broad range of box configurations, board types, and overhang conditions. Corrugated boxes fabricated from three board grades were tested under standardized conditions following TAPPI 804. A space-filling design systematically varied box dimensions and overhang magnitudes along the width, length, or both sides. The combined training dataset included 2,723 compression tests. An additional 600 compression tests from thirty commercial box designs formed an independent validation set used to evaluate model performance. A multiple linear regression model was developed, yielding an R² of 0.867 on training data, and 0.707 on validation data, with normally distributed residuals. Box height and edge crush test (ECT) values exhibited minimal influence within the studied ranges, while overhang magnitude, box perimeter and board type were the significant predictors of strength reduction. To further enhance predictive accuracy and capture nonlinear effects, different machine learning (ML) algorithms were evaluated. Cross validation was conducted for each of three best ML models to mitigate overfitting. These validated ML models provide packaging professionals with data driven tools to predict BCT loss due to pallet overhang, enabling sustainable, reliable and optimized packaging system design.
4:00pm - Whitepaper Updates: Temperature Monitoring, Real Time Monitoring, and Sustainable Management of Monitoring Devices
Location: Room: Valley of the Sun A/B
Mark Maurice
Sensitech
Richard Peck
RP Pharma Consulting Ltd
Guided by insights from recent industry surveys, the ISTA Pharma Committee has identified these topics as priorities for new industry guidance. This session provides an overview and progress update on three ISTA Pharma Committee whitepapers: Temperature Monitoring Whitepaper, Real Time Monitoring Considerations, and Sustainable Management of Temperature Monitoring Devices. Hear directly from the whitepaper leads as they share the scope, objectives, and key focus areas of each document, offering attendees early insight into the guidance being developed.
ISTA PCW 06 | Temperature Monitoring Whitepaper
Presenter:
Presenter:
Presenter:
ISTA PCW 06 | Temperature Monitoring Whitepaper
Presenter:
- Mark Maurice, ISTA Pharma Committee Board Member, Sensitech
Presenter:
- Richard Peck, ISTA Pharma Committee At Large Board Officer, RP Pharma Consulting Ltd
Presenter:
- Mark Maurice, ISTA Pharma Committee Board Member, Sensitech
4:30 - Future-Focused: ISTA Forum USA Interactive Wrap-Up
Location: Room: Valley of the Sun D/E
A.J. Gruber
ISTA
Join us for an interactive wrap-up session where your input matters! Through live polling, we’ll explore real-time insights into key challenges, research needs, best practices, sustainability strategies, damage rates, and emerging trends in optimizing packaging solutions. Be part of the conversation that drives insight and collaboration across the transport packaging community.
4:45 pm - Closing Remarks
Location: Room: Valley of the Sun A/B
Bryan Cardis
Cold Chain Technologies
Thursday, April 9, 2026 5:00pm - 5:15pm
Annual Meeting of ISTA Members
Join Nora Crivello, ISTA Global Board Chair, and A.J. Gruber, ISTA President & CEO, at the Annual Meeting of ISTA Members. Together, they will deliver board member updates, financial and membership reports for 2025, and share ISTA's strategic focus for 2026. This is an open meeting.
Thursday, April 9, 2026 6:30pm - 8:30pm
Forum Closing Celebration Dinner
Celebrate the closing of the 2026 ISTA Forum at one of Phoenix’s most eclectic venues—The Duce—for an evening of great food, drinks, games, and music. Unwind and connect with friends at this exclusive celebration in a truly unique setting. Transportation will be provided and a Forum name badge is required for entry. The reception is complimentary for attendees, and guest tickets can be purchased during registration. All attendees and guests must be 18 years or older.
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