DS Smith has announced the launch of TailorTemp, its innovation within temperature controlled packaging for the pharmaceutical industry. The packaging company is presenting the product for the first time at PharmaPack Europe 2025 (Paris) between the 22 and 23 January 2025.
TailorTemp packaging solution is designed to support the sustainability targets of pharmaceutical and biotech businesses, meeting their need to store and transport delicate medicinal products across multiple territories within rigorously controlled temperature environments.

TailorTemp is created from corrugated cardboard based material that is recyclable. The dimensions, insulating thickness, and coolant quantity are determined using a computer based parametric algorithm which has been co-developed by DS Smith in partnership with an independent laboratory specialising in thermal transfers. Designers can then use the outcomes of the modelling tool to fast track prototyping and validate solutions in real conditions.
The company has been able to demonstrate that this packaging solution can stay cool for up to 36 hours. The DS Smith component of the TailorTemp packaging solution, comprising an outer box and the insulant materials, is fully recyclable and 100% plastic free, representing a sustainable alternative to Expanded Polystyrene (EPS) for the packaging needs of pharmaceutical and biotech industries.

The packaging solution can be tailored to meet the requirements of each customer to provide them with an efficient solution, and the corrugated cardboard can be easily adapted to the dimensions of a product to reduce the overall size of the box, minimise the use of unnecessary materials, and prevent waste.
The DS Smith design team uses TailorTemp predictive modelling to predict temperature rises during storage or transit with a high level of accuracy. This data facilitates the efficient design process of solutions that are fit for purpose, and which are then final tested in the laboratory.
In addition, the research and development team is also already working on a new surface treatment, insulating materials, and process innovations for TailorTemp, to extend its ability to maintain cool temperatures for a further 96 hours and above.
The packaging solutions comprise three simple components – the outer box and two thermal liners, which can be easily assembled into the finished pack at the end of the production line or onsite by the customer. They are designed to ensure that they can be flexibly transported to customers in a flatpack format with both inbound and outbound space optimisation benefits. In comparison, Expanded Polystyrene (EPS) boxes are typically less versatile and usually need to be transported in a constructed form.
Marlena Hardy, innovation product manager, said: ‘TailorTemp demonstrates just how versatile and reliable fibre based material can be, not only to maintain temperatures in cold chain logistics, but also to deliver a recyclable outcome for customers seeking to meet sustainability targets. Design is everything, and our team is using specialist predictive modelling in the creation solutions for our pharma customers that are fit for purpose and then validating them in the laboratory without delay. We are delighted to have hit the crucial 36 hour milestone for cold chain storage and transportation, but the team is already hard at work on extending this to an even longer time period, and we think we will soon be able to extend TailorTemp’s ability to maintain cool temperatures to 96 hours and above.’
The use of EPS has come under scrutiny, making alternatives that are more readily recyclable of particular interest to businesses in the pharma and biotech industries. The EU Packaging and Waste Regulation (PPWR) will target Expanded Polystyrene (EPS) packaging solutions, the use of plastic, and other materials.
Marlena continued, Customers are increasingly demanding sustainable and recyclable packaging solutions, so the benefit of replacing EPS with a fibre based solution can’t be overlooked and bespoke EPS solutions can be cost prohibitive. We are excited for what we can achieve with pharma and biotech businesses.’
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