Tags: Storopack / Storopack Neopor

* Cooling pharmaceuticals on pallets

Storopack’s specialists introduce a lightweight thermo-pallet-shipper made from Neopor. The first user is Bayer Schering. The pharmaceutical manufacturer uses the thermo-shipper to deliver diagnostic products, subject to compulsory refrigeration, to destinations all over the world. With it’s light weight properties (less than 11 kg), the packaging made from Neopor offers high-grade insulation: for Bayer Schering the shipper was designed for 72 hours and a temperature range between +2°C and +8°C. For 53 hours the temperature inside does not exceed +25°C; thus, a defined temperature range is guaranteed for 125 hours in total.

According to tests in the climate chamber, the packaging can keep the range from 2 to 8°C for even more than 113 hours, depending on the temperature scenario. The bottom of the box with 575 litre volume inside has the same dimensions as a euro-pallet. The height of less than 120 cm is according to airfreight standard.

One person can assemble the pallet-shipper composed of six Neopor-modules with minimal effort. Thanks to the patented plug-in connection of the modules the shipper is solid and the modules’ joints are close. A cardboard shipping box is not necessary – the plug-in corpus is self-supporting and easy to pile. The packaging’s load capacity is 400 kg. The disassembled modules need minimal storage and transport capacities.

For comfortable loading from the front, both side panels and the rear panel are plugged in the bottom panel first. Then, an open cardboard ring, as high as the side panels, is placed inside. After loading the pallet-shipper, the cardboard is closed and the front panel is plugged in. The wall panels have cavities inside for eight thermal packs to be inserted from above. Thanks to the cardboard ring the goods loaded do not touch the thermal packs.

The packaging’s excellent insulation properties are due to Neopor, a plastic material related to expandable polystyrene (EPS). However, the silver colored Neopor’s insulation value is up to 20 percent higher than the insulation value of EPS, known under its trade name Styropor. A vacuum insulation panel by va-Q-tec (Wuerzburg, Germany) on the inner surface of the cover module supports the pallet-shipper’s energy efficiency. This panel reduces the emission and impact of heat from above additionally. The vacuum panel is protected by a twin-wall sheet.

Neopor has a fine-pored structure with a plane closed surface. Therefore, additional protection is not necessary. Self-adhesive labels can be fixed to the box without any problems. The shipper’s bottom is lightly ribbed; the ribs matching the space between the euro-pallet’s bars so that the shipper is fixed on the pallet. Another detail of this well-thought-out construction: Cavities in the cover module for brackets respectively straps avoid an overhanging of the shipper’s closure.

Based on the destinations, the pharmaceutical company Bayer Schering simulated for the tests various scenarios, i. e. temperature profiles supposed to be typical during transport; considering the means of transport used, seasons, as well as times of day and climate zones to which the products are delivered. Storopack tested the pallet-shipper incorporating these scenarios. For this purpose, Storopack’s research department has its own climate chamber. The climate chamber can generate temperature scenarios in the range of -25°C to +50°C. Temperature changes in the shipper are recorded by data loggers. The pallet-shipper exceeded the given requirements and the temperature was below the limit even longer than requested.

The volume of pharmaceuticals which need to be kept cool is permanently growing, and in turn, the requirements of logistics and packaging during transport have grown as well. For batches too small for a complete truck or too large for single insulation boxes, the use of thermo-pallet-shippers was established in the USA. Now, the demand for such shippers is also growing in Europe.

In cases of adequate transport volume, pallet-shippers are more economic than the use of many small boxes at the same time. Depending on their equipment, thermo-shippers are independent from active cooling for several days, as they do not need access to electricity for the use of a climate control unit. Further information is available under www.storopack.com.

Storopack is a specialist in the field of protective packaging. Its product portfolio encompasses both customised and flexible packaging systems and their integration into customer packaging processes. The services provided by the internationally active company group based in Metzingen (Germany) are performed by the two divisions Molding and Packaging.

The Molding Division is a specialist in customized protective packaging solutions and technical moldings made of expanded foam such as EPS (Styropor®), EPP (expandable polypropylene) or Neopor, catering to a wide range of different industrial sectors. The materials are made particularly attractive by a range of benefits including insulation, shock absorption, durability and low weight. In our Technology Center, we design moldings using state-of-the-art technologies such as CAD development, CNC prototyping and tool design. Testing facilities include a drop testing system and climatic chamber. Our complete production process is designed to be environmentally friendly and uses water vapor. Our Molding Division is present in Europe and China with certified producing locations.

Storopack UK Limited:

Richard Pulfrey, 8 Julian Road, Roman Ridge Industrial Estate, GB – Sheffield S9 1FZ, Great Britain; Phone +44 114 249 2004 – Fax +44 114 249 2006; packaging.uk@storopack.com -  www.storopack.co.uk

Headquarter:

Storopack, Hans Reichenecker GmbH, Untere Rietstrasse 30, 72555 Metzingen, Germany; www.storopack.com