The movement of pharmaceuticals at strict five-degree conditions has historically been limited by technology, cost, and operational complexity. Active containers provide precision but are heavy, expensive, and logistically cumbersome. As a result, the market has begun exploring more nuanced approaches, combining infrastructure, process innovation, and network design to achieve the same outcome. This shift signals a broader change in the cold chain: success is no longer solely defined by the sophistication of a container but by the orchestration of multiple touchpoints. Building up pallets outside airports, integrating phase-change materials, and creating seamless transition points demonstrates a systems-based approach, where every stage of transit is controlled to maintain temperature integrity.
This evolution reflects a recognition that cold chain logistics is as much an engineering problem as it is a commercial one. By strategically locating hubs, coordinating with trusted forwarders, and leveraging specialised equipment like cool dollies, carriers are now able to maintain precise temperatures without relying solely on high-cost active containers. The model also underscores a growing industry understanding that end-to-end control is essential: it is not enough to manage temperature at origin; each handling point, each ramp transfer, and each layover presents a potential risk to product integrity, demanding a holistic approach to design and execution.
“To move five degrees is very complicated, and the only solution has traditionally been active stroke hybrid containers, which are expensive and heavy. We manage this without them by using infrastructure and equipment that can maintain temperature. In some countries, we build pallets outside the airport with our forwarding partners, while maintaining ambient temperature consistently to ensure long-lasting performance,” Julian Sutch, Head of Cool Chain Products, Emirates SkyCargo, said. “This process allows us to maintain quality without the extreme cost and complexity of active containers. It also gives our customers confidence that their pharmaceuticals are protected throughout the journey. We have observed that this method improves operational efficiency while reducing environmental impact compared with using large volumes of single-use passive packaging.”
The orchestration of these components demonstrates that logistics innovation is increasingly about operational intelligence rather than equipment alone. Airlines that integrate environmental control systems, strategic hub locations, and staff trained to maintain chain integrity effectively create a competitive advantage that cannot be easily replicated. By embedding temperature protection into the operational workflow itself, rather than treating it as an add-on, carriers are mitigating risk in ways that redefine the value proposition for customers.
“We combine this with our freighters, which have a stringent temperature control system to maintain five degrees, and with origin and destination pairing. For example, using a passenger plane from Brussels with cool dolly capability, we can build pallets, transport them to the airport, load them onto the aircraft, and ensure they remain at five degrees all the way to Dubai and onward to Singapore, where cool dollies are available on the ramp,” Sutch added. “Either a freighter or a cool dolly service is essential to maintain the cold chain. This approach allows for minimal handling time and fewer points of potential temperature deviation. We also coordinate closely with our staff and ground partners to ensure a seamless handover at each stage. The system is designed to work on major lanes globally, creating a replicable model for high-value pharmaceutical transport.”
Network design and lane risk management
Temperature-sensitive shipments are only as reliable as the network that carries them. Even the most sophisticated origin hub offers no guarantees if intermediate points introduce risk. Lane risk assessments are therefore central to modern cold chain strategy. By evaluating potential vulnerabilities — whether due to inadequate ramp infrastructure, regulatory barriers, or environmental extremes — carriers can deploy the right mix of containers, equipment, and procedural safeguards to preserve product integrity.
The emphasis on destination risk highlights a significant evolution in cold chain thinking. Previously, the focus was largely on origin-to-hub transit; today, carriers are designing for end-to-end protection, ensuring that each touchpoint is accounted for. This requires detailed knowledge of regional handling capabilities, environmental conditions, and local regulations. Such intelligence enables the creation of tailored solutions for each shipment, where packaging, routing, and transshipment protocols are calibrated to the specific demands of the route.
“Lane risk assessments are essential. You can have an excellent origin hub and a great hub in Dubai, but the risk emerges when shipments reach some regions where treatments are needed urgently. Protecting the shipment across the entire lane is critical to maintaining integrity and mitigating potential losses,” Sutch outlined. “We analyse each route for temperature and handling risks, and we adapt packaging or procedures accordingly. Working closely with partners at each stop allows us to pre-empt potential disruptions. It also informs the type of container and the handling methods to be applied throughout the journey.”
The ability to identify and manage these risk points creates a competitive advantage. Airlines that understand both the product and the network can offer reliable, consistent service, even in regions with limited infrastructure. This proactive approach turns the traditional vulnerability of multi-leg shipments into a controlled, optimised process, giving shippers confidence that their temperature-sensitive cargo is protected throughout the journey.
“With comprehensive knowledge of packaging performance and ground handling capabilities across our network, we help customers select the right solution for each shipment, ensuring protection from origin to destination,” Sutch explained. “We also review local handling procedures and provide guidance for any improvements required. This allows us to maintain the cold chain even in regions with challenging infrastructure. Each shipment is treated individually, allowing us to anticipate and mitigate risks before they can affect the cargo.”
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Author: Edward Hardy
