Aeropowder launches feather based brand PluumoPlus for thermal packaging in US

Aeropowder, a UK based sustainable materials company currently operating in Europe, has launched its patented PluumoPlus thermal insulation products to US customers, with local production beginning in Q1 2027. The launch includes deep frozen and refrigerated thermal packaging solutions, as well as the new PluumoPlus 2-8°C Insulated Mailer for specialty pharmacies.

The US launch comes as demand for temperature controlled healthcare logistics grows. Specialty medicines account for more than half of US medicine spending, according to the IQVIA Institute, and US pharmacies dispensed an estimated $293 billion of specialty drugs in 2025, according to the Drug Channels Institute. Shippers also face pressure to cut the plastic waste generated by insulated packaging.

Feathers have evolved over millions of years to be strong, lightweight and to trap air exceptionally well. PluumoPlus harnesses these properties in an engineered insulation material made from recycled feathers sourced from the bedding and clothing industries. The company says its thermal performance is up to 30% better than current natural alternatives and competes with high end polyurethane foam.

The PluumoPlus Mailer puts this performance to work. The company has qualified the mailer to maintain 2 to 8°C for 53 hours in a summer configuration and for 96 hours in a winter configuration against modified ISTA 7E temperature profiles. That offers up to 45% savings in freight costs, through smaller volumetric shipping or a move from air to ground.

PluumoPlus products are already supplied in Europe to customers including GLP-1 distributors and clinical logistics companies.

Dr Ryan Robinson, CEO and founder of Aeropowder, said: ‘The healthcare supply chain needs solutions that perform better and are more sustainable, and that is exactly what PluumoPlus delivers. We are keen to work with life science companies, logistics providers and packaging companies in the US who need high performance without compromising on sustainability.’

In the US, PluumoPlus will be manufactured in partnership with ColdCorr Insulated Packaging, a cold chain packaging manufacturer with locations in Arizona, Kentucky and Tennessee, to facilitate the local production of the product.

Chris Poore, director at ColdCorr Insulated Packaging, said: ‘I have never seen performance like PluumoPlus from any other natural material. There is a clear gap in the market for a high-performance sustainable solution that consistently delivers extended performance under demanding conditions, and PluumoPlus does exactly that.’

Aeropowder intends to scale PluumoPlus to millions of units supplied into the US market annually, establishing it as the new standard for shippers who want premium thermal performance beyond existing natural materials, without single use plastic foams.