• CCT reduced the vaccine manufacturer’s reship rate from 1.9% to 0.3%, with zero temperature excursions across 20,000 shipments, supported by real-time monitoring, predictive analytics and 24/7 oversight.
• Reusable EcoFlex shippers and CCT ReNew reverse logistics prevented more than 2 million pounds (907,000 kg) of material from going to landfill, while transport optimisation reduced carbon usage.
• The integrated thermal assurance programme generated approximately US$12 million in cost savings, driven by reduced product loss, more efficient freight decisions and improved packaging selection.

Cold Chain Technologies (CCT) has reported data from a key vaccine distribution project which ultimately helped to eliminate temperature excursions, reduce reships by 84%, and prevent 2 million pounds (907,000kgs) of waste to landfill.

Before partnering with CCT, the vaccine manufacturer was experiencing challenges within its existing cold chain distribution model. A lack of real-time intelligence and predictive oversight was contributing to compromised deliveries and product loss, with a recorded reship rate of 1.9%.

Sustainability was another challenge. The original packaging solutions in place were not reusable, and the transport methods utilised were not being assessed or optimised for carbon efficiency.

When the manufacturer decided to appoint a new provider, CCT’s end-to-end thermal assurance approach offered a more strategic, outcome-driven alternative.

CCT’s thermal assurance programme was built around its Customer Assurance and Resource Excellence (C.A.R.E) service which included EcoFlex (CCT’s leading reusable parcel shipper) and MedAssure, CCT’s digital application, which provides real-time monitoring, predictive analytics and insights, and round the clock monitoring. Reusable EcoFlex containers were continuously tracked through transit, and data gathered from these shipments, combined with insights from CCT’s wider network, fed predictive modelling capabilities.

Supported by continuous monitoring from CCT C.A.R.E specialists, MedAssure facilitated a proactive approach to distribution, providing real-time risk detection and resolution, with tactics such as shipment accelerations or route intercepts deployed as required.

As a result, the reship rate dropped dramatically from 1.9% to 0.3%, with zero temperature excursions recorded over 20,000 shipments. This, alongside enhanced downstream communication capability, led to greater trust and stronger collaboration with stakeholders such as pharmacies, supporting better patient outcomes.

From a sustainability perspective, the selection of CCT’s reusable lease-and-return EcoFlex shipping containers, coupled with its CCT ReNew reverse logistics service, delivered clear results. By stepping away from single-use packaging, the manufacturer was able to save more than 2 million pounds (907,000kgs) of material from being sent to landfill, as well as reducing carbon usage through careful optimisation of transportation.

As a result of CCT’s strategic thermal assurance approach, the manufacturer achieved cost savings of approximately $12 million through reduced product loss, more efficient freight decisions and improved packaging selection.

David Webber, Senior Global Marketing Manager at Cold Chain Technologies, said: “The success of this project lies in CCT’s integrated approach. The adoption of a reusable shipper, CCT EcoFlex, along with the real-time visibility and predictive analytics offered by the MedAssure platform, supported by 24/7 oversight and management by CCT C.A.R.E. specialists enhanced the performance of the distribution program, reduced costs and significantly improved sustainability outcomes.”

“Projects like this really demonstrate the benefits of using a single thermal assurance provider that can bring together a comprehensive offering of products, digital solutions and service offerings. This helps drive quick decisions and a measurable impact.”

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