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.

Containment force is widely used as a practical containment metric to judge stretch-wrap quality and, in many operations, as a primary go/no-go criterion for unit-load stability. While containment force is valuable, it does not always predict how a palletized load will behave under horizontal dynamic events typical of transport. In practice, loads can present “in-spec” containment force values yet still shift, deform or lose stability when subjected to horizontal acceleration and transient inputs—creating false confidence and inconsistent outcomes across sites. 

This presentation proposes an applied framework that keeps containment force as an important baseline indicator but avoids non-conclusive decisions by adding two critical elements. First, it emphasizes controlling film use through adequate pre-stretch and, when appropriate, operating beyond the film’s NDR region to reach a more stable, repeatable containment state. Second, it recommends confirming performance with horizontal dynamic tests representative of transport conditions, rather than relying on static containment force targets alone. 

The outcome is a more robust, transport-performance-oriented evaluation approach: clarifying when containment force is informative and when it becomes ambiguous, and showing how combining pre-stretch/NDR control with dynamic validation helps packaging teams reduce variability, improve repeatability, and avoid non-conclusive acceptance decisions based solely on containment force —ultimately reducing the risk of in-transit failures despite “passing” containment-force targets. 

Pass/fail testing is widely used as the final approval process for packaging. The outcome is binary and that simplicity hides what matters most: how much performance margin actually exists against reality, where a design is vulnerable, or how much material is present without purpose.

This blind spot cuts both ways. Packages can pass recognised test protocols and still fail in distribution when handling intensity, stacking behaviour, or logistics conditions differ from what is assumed. At the same time, laboratory tests can be more severe than real life, meaning additional safety margins are added simply to ensure a pass. A “PASS” tells us that survival was achieved in the lab but not how far from failure the system in reality is.

This session argues that the real issue is not testing intensity, but information loss. Impact response, deformation behaviour, performance under compression, and vibration sensitivity are measurable, repeatable signals that already exist and can be translated into meaningful test data. When ignored, they collapse into a single yes/no verdict; when used, they reveal margin‑to‑failure and true performance gradients. Rather than replacing existing protocols, this session challenges the comfort of pass/fail thinking. A controlled failure measurement that reveals margin, sensitivity, and design limits is more informative than a passing test result without numbers, which simply hides over‑engineering. The goal is not weaker packaging, but better‑informed packaging decisions, based on observed risk behaviour rather than assumption.

• 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).

The rapid evolution of retail is fundamentally transforming logistics networks and redefining the role of packaging within the supply chain. The shift from traditional pallet-based distribution to highly fragmented, parcel-driven delivery models—fueled by e-commerce and omnichannel strategies—has introduced new challenges in product protection, cost efficiency, and sustainability.

This session explores the critical trends shaping this transformation, including the growing complexity of last-mile logistics, increased handling touchpoints, and rising consumer expectations for speed, visibility, and environmental responsibility. It highlights how packaging is no longer just a protective layer, but a strategic enabler of supply chain performance, directly impacting damage rates, operational costs, and customer experience.

Drawing on applied industry experience and real-world cases, the presentation will provide a structured perspective on how organizations can redesign packaging systems to align with modern logistics realities. Key topics include right-sizing strategies, packaging optimization for parcel distribution, integration of digital technologies for traceability, and the balance between sustainability goals and operational constraints.

Participants will gain practical insights into how to build more resilient, efficient, and consumer-centric supply chains by integrating packaging engineering with logistics and retail strategies.

1. How inner cushioning, cell separation, and vent path geometry shape what happens at the package boundary when one cell fails
2. What package-level instrumentation actually captures during a runaway event, and what it misses
3. Where UN qualification ends and shipper-level performance evidence begins, in practical terms