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The 5 design stages of a customised insulated packaging solution

Our 3 standard packaging ranges respond to numerous specifications with several types of temperature-controlled packaging for domestic or international transportation: insulated pouches, refrigerated boxes, palletised-insulated containers. However our Design Office can help with specific requirements. This involves either adapting a standard packaging solution, or creating a new packaging solution. The development process of customised packaging consists of 5 stages.

Custom-design of a packaging

1. Define the specifications 


The specifications are the foundation for the project design of an insulated or refrigerated packaging solution. As the core document for development, and reference throughout the development of the project, it allows us to define your requirements in terms of storage temperature, product volume, thermal properties and logistical constraints. 

“The specifications allow us to bring together the expectations of the user and the technical constraints. Occasionally some characteristics desired by the user are not feasible: our role is to inform them beforehand. We review the specifications together and adjust them according to the user’s most important criteria and our own recommendations.” 

Jérémy Clerfeuille, Head of the Design Office.


2. Calculate the size of the packaging

Firstly, our engineers calculate the thermal balance of the packaging with the help of software specifically developed by Sofrigam. This allows pre-sizing of the packaging according to its energy intake and insulating properties. The thermal balance data are then input into the digital simulation software. This simulation refines the pre-sizing data. We define precise measuring points and ensure that the temperature is consistent. 


3. Perform POC (Proof Of Concept) tests

The climatic chambers simulate the logistics profile that the packaging will be subjected to during transportation. Temperatures, humidity: the climatic conditions are reproduced in order to analyse the impact on the payload. These actual temperature tests are carried out by our partner Ater Métrologie.


4. Qualify the packaging

After the temperature tests: the performance tests. We draw up a qualification dossier specific to the insulated packaging solution. It provides all of the information on the design (materials used, loading method, etc.), and the protocol for the climatic tests (number of tests carried out, simulation products used, calibration of measurement devices, etc.). It allows the pharmaceutical laboratory to justify the efficiency of the packaging solution to the authorities. 


5. Train teams and provide technical support 

As soon as the insulated packaging solution is delivered, the Design Office teams provide technical support to ensure the efficiency of the packaging solution. They can train you to use the packaging solution at your premises, or by a 3D video tutorial. They then provide continuous technical support to improve the solution if necessary.