Market Shift Case Study:

Replacing Active Heating and Cooling Shipping

Systems with Passive Pallet Shippers

International Zonal Ambient Profile Development,

Maximize Packaging Design Optimization

Existing Situation

Minimal Passive Solutions for International Shipping

Pallet and Less Than Pallet

Current Solution

Active Systems

Small Passive PUR Systems

Complex Logistics

Destination consignee can receive an active unit

Ability unavailable to unload and or move containers

Multiple small passive shippers to destination

Remote/Difficult Locations (ie. Embargoed countries)

Shipping schedule is being based on availability of active units for leasing and the

ability of the destination to receive units

Lease Cost for Active Units

2

Existing SituationOperational challenges

Labor Intensive (Packaging and TSA Screening)

Distribution may be incapable of shipping to locations that do not have documented

qualification

License approvals for foreign markets may be delayed if qualification documentation is

not available

Equipment Failures

Risk of mechanical failure

In flight

On ground

User error

3

Business GoalsReduce Complexity

Logistics

Cost Reductions

Reduce Labor

Reduce Packaging

Eliminates Lease Cost

Reduce Freight

Reduce Total Cost

Better Flight Availably

Containers onsite

Fast Shipping Response Time

No waiting for containers to be available, ship and arrive

Reduce Total Cost

4

Development Criteria Design and qualification of passive containers based on international temperature

profiles will produce reports that assure global agencies that the method of shipment

was designed specifically to maintain product temperatures when shipping to their

locations, and not require dedicated lane qualifications for that country.

Ambient Profile

International Zonal Profiles to be used

Temperature data collected in conjunction with Sanofi freight forwarder

Data was analyzed and evaluated by Sanofi in collaboration with Sonoco-Thermosafe

Zones were compressed from the initial 13 identified

5

Development Criteria

Temperature Criteria

2°C to 8°C with only initial hour for allowable excursions due to TOR

Continuous monitored with a datalogger in field

Dimensions

ID Requirements

40 x 48 x 53

OD Requirements

Narrow bodied planes vs. wide bodied planes

Test Material

Bracketed Approach; Minimum and Maximum Thermal Mass

Distribution Testing

ISTA 2B

6

Ambient Profile Development Shipping lane data obtained from transportation provider for 12 global zone

7

Low High Low High

1 60 8.6 25.5 5.0 14.4 17.3 16.8 758.4 12.6

2

3

4 88 1.1 16.2 5.0 7.5 7.8 7.5 170.4 1.9

5 73 4.4 20.9 5.0 8.6 10.3 9.3 295.1 4.1

6 87 0.9 17.1 5.0 7.3 7.8 7.2 163.3 1.9

7 149 -4.3 19.1 3.9 8.2 7.1 6.4 107.8 0.7

8 160 1.6 21.0 5.0 7.4 7.2 6.3 132.3 0.8

9 93 -2.5 22.8 5.0 9.3 11.1 9.5 298.8 3.2

10 90 15.6 24.2 5.0 17.9 19.5 19.3 1035.5 11.5

11 118 10.0 25.8 5.0 18.9 19.4 18.7 894.1 7.6

12 125 1.1 16.3 4.7 8.5 7.3 6.1 121.9 1.0

Winter Season

Zones Duration

Profile Temp.

Range

Theoretical Model

ResultsMean

Kinetic

Temp.

Average

Profile Temp.

Area Under

the CurveAUC/hr

Raw Data

Design Profile

Profile Grouping

Heat Transfer Concepts

Temperature Assured Packaging systems utilize conduction to facilitate heat

transfer

Air circulation is present in all packaging systems, but it is incidental not

designed

Heat transfer by air i.e. Convection becomes more significant as package

size increases

Convection is defined as heat transfer due to the movement of a fluid on a

solid surface.

There are two types of convection heat transfer

Forced Convection – utilized in Active Shipping systems, cold air is

circulated in the container using a fan

Natural Convection – utilized in Passive Pallet Shippers, uses principle of

Buoyancy.

8

Active vs. Passive Shippers

9

• Active Shipper

• Requires constant power source

• High cost

• Special handling protocol

• Passive Shipper

• Cost Effective

• Reusable

• No Power Source

• Readily Available

Convection Based Thermal Design

Use Buoyancy effect to establish a convection current in the pallet shipper

10

Gravity

Thermal Modeling

11

Quarter Symmetry Model

Convection Channels*

*Patent Pending

Thermal Modeling

12

Gravity

Hot Air

Cold Air

• A temperature gradient on the air

channel results in setting up a

convection current

Thermal Modeling

13

• 3D Thermal Modeling

provides a complete

temperature map of the

product

• Multiple configurations can

be quickly and accurately

simulated

Benefits of Phase Change Materials

14

PureTemp PT4 is utilized to control

convection air temperature in pallet shipper

Prevents Cold Shock

Hold a variety of tight temperature

tolerances

Increase Weight to Payload Efficiency

(WPE)

Significantly increase Payload to Box Ratio

(PBR)

Simplify pack-out

Extend transport durations

Produce lower total cost of ownership

Puretemp phases at 4 C

Water Brick phases at 0

C

15

Convection Pallet Shipper

Chamber Test – Sanofi Ambient Profile

16

Chamber Tests – Sonoco-Thermosafe

Global Profiles

17

Hot Season Test

Winter Season Test

Summer Packout

Winter Packout

Patented Convection Technology

18

Convection Pallet Shipper has been registered as a US and International

Patent in 2012 by Sonoco ThermoSafe™

Benefits of Convection Pallet Shipper

Utilize Natural Convection to maintain product temperatures

Minimize thermal contact with ambient

Top and Bottom Refrigerant configuration

Simple and efficient to packout

Significantly reduce amount of refrigerant

compared to 6-sided design

Pallet in Pallet design

Future Development

19

Convection based technology is being applied for a extended

line of shippers

Full Pallet

Half Pallet

•

Impact to Operations

Future State:

Logistics Complexity

Eliminates/Reduces ordering containers

Lessens concern of supply chain for active units

Increased flight options /availability

Operational Efficiencies

Reduced Labor

Reduced Packaging Cost

Reduced Freight Cost

Improved scheduling forecasting for labor

20

Impact to Operations

Continued partnership with our vendors as we collaborate on projects

Data Collection Global Ambient Profile Generation Qualified Shipper

Ship to Locations (before vs. after)

Positioning and return of active units will be negated/limited

Savings

$3M+ in Packaging Savings

Freight Savings TBD

Savings on express fees

Reduces over time cost

21