Insulated shipping container

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Insulated shipping containers are a type of packaging used to ship temperature sensitive products such as foods, pharmaceuticals, organs, blood, biologic materials, vaccines [1] and chemicals. They are used as part of a cold chain to help maintain product freshness and efficacy. The term can also refer to insulated intermodal containers or insulated swap bodies.

Contents

Construction

Shipment of vaccine: PUR insulated box, gel packs, temperature monitor Cold control packaging.jpg
Shipment of vaccine: PUR insulated box, gel packs, temperature monitor

A variety of constructions have been developed. [2] [3] [4] [5] An insulated shipping container might be constructed of:

  1. a vacuum flask, similar to a "thermos" bottle
  2. fabricated thermal blankets or liners
  3. molded expanded polystyrene foam (EPS, styrofoam), similar to a cooler
  4. other molded foams such as polyurethane, polyethylene
  5. sheets of foamed plastics
  6. Vacuum Insulated Panels (VIPs)
  7. reflective materials: (metallised film)
  8. bubble wrap or other gas filled panels
  9. other packaging materials and structures

Some are designed for single use while others are returnable for reuse. Some insulated containers are decommissioned refrigeration units. Some empty containers are sent to the shipper disassembled or “knocked down”, assembled and used, then knocked down again for easier return shipment.

Shipping containers are available for maintaining cryogenic temperatures, with the use of liquid nitrogen. Some carriers have these as a specialized service [6]

Use

United States Army Medical Materiel Agency video showing how containers are packed to maintain constant cold temperatures.

Insulated shipping containers are part of a comprehensive cold chain which controls and documents the temperature of a product through its entire distribution cycle. The containers may be used with a refrigerant or coolant such as: [7]

A digital Temperature data logger or a time temperature indicator is often enclosed to monitor the temperature inside the container for its entire shipment.

Labels and appropriate documentation (internal and external) are usually required.

Personnel throughout the cold chain need to be aware of the special handling and documentation required for some controlled shipments. With some regulated products, complete documentation is required.

Design and evaluation

The use of “off the shelf” insulated shipping containers does not necessarily guarantee proper performance. Several factors need to be considered: [8]

In specifying an insulated shipping container, the two primary characteristics of the material are its thermal conductivity or R-value, and its thickness. These two attributes will help determine the resistance to heat transfer from the ambient environment into the payload space. The coolant material load temperature, quantity, latent heat, and sensible heat will help determine the amount of heat the parcel can absorb while maintaining the desired control temperature. Combining the attributes from the insulator and coolant will allow analysis of expected duration of the insulated shipping container system. Testing of multi-component systems is needed. [9]


It is wise (and sometimes mandatory) to have formal verification of the performance of the insulated shipping container. Laboratory package testing might include ASTM D3103-07, Standard Test Method for Thermal Insulation Performance of Packages, ISTA Guide 5B: Focused Simulation Guide for Thermal Performance Testing of Temperature Controlled Transport Packaging, and others. [10] In addition, validation of field performance (performance qualification) is extremely useful.

Specialists in design and testing of packaging for temperature sensitive products are often needed. These may be consultants, independent laboratories, universities, or reputable vendors. Many laboratories have certifications and accreditations: ISO 9000s, ISO/IEC 17025, etc.

Environmental Impact

Parcel to pallet sized insulated shipping containers have historically been single-use products due to the low-cost material composition of EPS and water-based gel packs. The insulation material typically finds its way into landfill streams as it is not readily recyclable in the United States.

The development of reusable high-performance shipping containers have been shown to reduce packing waste by 95% while also contributing significant savings to other environmental pollutants. [11]

See also

Related Research Articles

<span class="mw-page-title-main">Refrigeration</span> Process of moving heat from one location to another in controlled conditions

Refrigeration is any of various types of cooling of a space, substance, or system to lower and/or maintain its temperature below the ambient one. Refrigeration is an artificial, or human-made, cooling method.

<span class="mw-page-title-main">Thermal insulation</span> Minimization of heat transfer

Thermal insulation is the reduction of heat transfer between objects in thermal contact or in range of radiative influence. Thermal insulation can be achieved with specially engineered methods or processes, as well as with suitable object shapes and materials.

<span class="mw-page-title-main">Vacuum flask</span> Insulated storage vessel

A vacuum flask is an insulating storage vessel that greatly lengthens the time over which its contents remain hotter or cooler than the flask's surroundings. Invented by Sir James Dewar in 1892, the vacuum flask consists of two flasks, placed one within the other and joined at the neck. The gap between the two flasks is partially evacuated of air, creating a near-vacuum which significantly reduces heat transfer by conduction or convection. When used to hold cold liquids, this also virtually eliminates condensation on the outside of the flask.

<span class="mw-page-title-main">Polystyrene</span> Polymer resin widely used in packaging

Polystyrene (PS) is a synthetic polymer made from monomers of the aromatic hydrocarbon styrene. Polystyrene can be solid or foamed. General-purpose polystyrene is clear, hard, and brittle. It is an inexpensive resin per unit weight. It is a poor barrier to air and water vapor and has a relatively low melting point. Polystyrene is one of the most widely used plastics, with the scale of its production being several million tonnes per year. Polystyrene is naturally transparent, but can be colored with colorants. Uses include protective packaging, containers, lids, bottles, trays, tumblers, disposable cutlery, in the making of models, and as an alternative material for phonograph records.

<i>R</i>-value (insulation) Measure of how well an object, per unit of area, resists conductive flow of heat

In the context of construction, the R-value is a measure of how well a two-dimensional barrier, such as a layer of insulation, a window or a complete wall or ceiling, resists the conductive flow of heat. R-value is the temperature difference per unit of heat flux needed to sustain one unit of heat flux between the warmer surface and colder surface of a barrier under steady-state conditions. The measure is therefore equally relevant for lowering energy bills for heating in the winter, for cooling in the summer, and for general comfort.

<span class="mw-page-title-main">Radiant barrier</span>

A radiant barrier is a type of building material that reflects thermal radiation and reduces heat transfer. Because thermal energy is also transferred by conduction and convection, in addition to radiation, radiant barriers are often supplemented with thermal insulation that slows down heat transfer by conduction or convection.

A vacuum insulated panel (VIP) is a form of thermal insulation consisting of a gas-tight enclosure surrounding a rigid core, from which the air has been evacuated. It is used in building construction, refrigeration units, and insulated shipping containers to provide better insulation performance than conventional insulation materials.

<span class="mw-page-title-main">Cooler</span> Insulated box used to keep food or drink cool

A cooler, portable ice chest, ice box, cool box, chilly bin, or esky (Australia) is an insulated box used to keep food or drink cool.

A coolant is a substance, typically liquid, that is used to reduce or regulate the temperature of a system. An ideal coolant has high thermal capacity, low viscosity, is low-cost, non-toxic, chemically inert and neither causes nor promotes corrosion of the cooling system. Some applications also require the coolant to be an electrical insulator.

<span class="mw-page-title-main">Ice pack</span> Filled bag designed to be frozen

An ice pack or gel pack is a portable bag filled with water, refrigerant gel, or liquid, meant to provide cooling. They can be divided into the reusable type, which works as a thermal mass and requires freezing, or the instant type, which cools itself down using chemicals but can only be used once. The instant type is generally limited to medical use as a cold compress to alleviate the pain of minor injuries, while the reusable type is both used as a cold compress and to keep food cool in portable coolers or in insulated shipping containers to keep products cool during transport.

<span class="mw-page-title-main">Cold chain</span> Low-temperature supply chain

Cold chain is defined as the series of actions and equipment applied to maintain a product within a specified low-temperature range from harvest/production to consumption. An unbroken cold chain is an uninterrupted sequence of refrigerated production, storage and distribution activities, along with associated equipment and logistics, which maintain a desired low-temperature interval to keep the safety and quality of perishable or sensitive products, such as foods and medicines. In other words, the term denotes a low temperature-controlled supply chain network used to ensure and extend the shelf life of products, e.g. fresh agricultural produce, seafood, frozen food, photographic film, chemicals, and pharmaceutical products. Such products, during transport and end-use when in transient storage, are sometimes called cool cargo. Unlike other goods or merchandise, cold chain goods are perishable and always en-route towards end use or destination, even when held temporarily in cold stores and hence commonly referred to as "cargo" during its entire logistics cycle. Adequate cold storage, in particular, can be crucial to prevent quantitative and qualitative food losses.

Insulation may refer to:

<span class="mw-page-title-main">Building insulation</span> Material to reduce heat transfer in structures

Building insulation is material used in a building to reduce the flow of thermal energy. While the majority of insulation in buildings is for thermal purposes, the term also applies to acoustic insulation, fire insulation, and impact insulation. Often an insulation material will be chosen for its ability to perform several of these functions at once.

<span class="mw-page-title-main">Package cushioning</span> Protective packaging

Package cushioning is used to protect items during shipment. Vibration and impact shock during shipment and loading/unloading are controlled by cushioning to reduce the chance of product damage.

<span class="mw-page-title-main">Thermal bag</span>

A thermal bag is a type of thermally insulated shipping container in the form of a bag which can be carried, usually made of thermally insulating materials and sometimes a refrigerant gel. It is used to help maintain the temperature of its contents, keeping cold items cold, and hot items hot.

A shipping container is a container with strength suitable to withstand shipment, storage, and handling. Shipping containers range from large reusable steel boxes used for intermodal shipments to the ubiquitous corrugated boxes. In the context of international shipping trade, "container" or "shipping container" is virtually synonymous with "intermodal freight container", a container designed to be moved from one mode of transport to another without unloading and reloading.

<span class="mw-page-title-main">Corrugated box design</span> Process of matching design factors for corrugated fiberboard boxes

Corrugated box design is the process of matching design factors for corrugated fiberboard boxes with the functional physical, processing and end-use requirements. Packaging engineers work to meet the performance requirements of a box while controlling total costs throughout the system. Corrugated boxes are shipping containers used for transport packaging and have important functional and economic considerations.

<span class="mw-page-title-main">Drug packaging</span> Packaging for pharmaceutical preparations

Pharmaceutical packaging is the packages and the packaging processes for pharmaceutical preparations. It involves all of the operations from production through drug distribution channels to the end consumer.

<span class="mw-page-title-main">Package testing</span>

Package testing or packaging testing involves the measurement of a characteristic or property involved with packaging. This includes packaging materials, packaging components, primary packages, shipping containers, and unit loads, as well as the associated processes.

A temperature data logger, also called temperature monitor, is a portable measurement instrument that is capable of autonomously recording temperature over a defined period of time. The digital data can be retrieved, viewed and evaluated after it has been recorded. A data logger is commonly used to monitor shipments in a cold chain and to gather temperature data from diverse field conditions.

References

  1. Packing Vaccines for Transport during Emergencies (PDF), USHHS Centers for Disease Prevention and Control, 2015, retrieved 4 December 2020
  2. US 5924302,Derifield, Rodney M.,"Insulated shipping container",published 1999-07-20, assigned to Foremost In Packaging Systems Inc.
  3. US 5201868,Johnson, Roberta L.,"Insulated shipping container",published 1993-04-13, assigned to Rock-Tenn Company
  4. US 6868982,Gordon, Lawrence A.,"Insulated shipping container and method of making the same",published 2005-03-22, assigned to Cold Chain Technologies Inc.
  5. US 6119465,Mullens, Patrick L.&Emmel, Gregg,"Shipping container for storing materials at cryogenic temperatures",published 2000-09-19
  6. "UPS Temperature True® Cryo: UPS - United States". United Parcel Service . Archived from the original on September 4, 2019. Retrieved May 5, 2021.
  7. Matsunaga, K; Burgess, Lockhart (March 2007). "Two methods for calculating the amount of refrigerant required for cyclic temperature testing of insulated packages". Packaging Technology and Science. 20 (2): 113–123. doi: 10.1002/pts.747 . S2CID   135844034.
  8. Choi, Seung-Jin; Burgess (November 2007). "Practical mathematical model to predict the performance of insulating packages". Packaging Technology and Science. 20 (6): 369–380. doi:10.1002/pts.762. S2CID   136558384.
  9. Wang, K (March 2020), "Investigation of the effect of thermal insulation materials on packaging performance", Packaging Technology and Science, 33 (6): 227–237, doi: 10.1002/pts.2500
  10. Singh, S P; Burgess, Singh (2008). "Performance Comparison of Thermal Insulated Packaging Boxes, Bags and Refrigerants for Single-parcel Shipments". Packaging Technology and Science. 21: 25–35. doi:10.1002/pts.773. S2CID   14036303 . Retrieved 9 Oct 2018.
  11. Goellner, Kai N.; Sparrow, Eph (2013-11-26). "An environmental impact comparison of single-use and reusable thermally controlled shipping containers". The International Journal of Life Cycle Assessment. 19 (3): 611–619. doi: 10.1007/s11367-013-0668-z . ISSN   0948-3349.