Cryolux Australia Cold Chain Solutions Design Process

 

Regulating Temperature Within Standard Shipment Packaging


The Most effective ways to maintain consistent temperature is to use High-Quality Cryolux Reusable ice packs in combination with the validated Performance Cryolux insulated shippers / Ice Chests. During the transport of large volume of cold products, temperatures are regulated by vehicles equipped with powered refrigeration and freezer units and Refrigerated transport has always been an expensive choice.

There are still a lot of areas where refrigeration is not an option. Once these goods are removed from the refrigerated  environment , They are usually transported in insulated ice boxes with refrigerants to maintain the temperature and the Chill times usually vary based on the quality of insulation and volume of refrigerants the time.

 
Insulated Shipping For Long Transit Times


If your intend to ship temperature sensitive goods with long transit times , Apart from the expensive refrigerated Transport Option , Cryolux ice chests can be used with Cryolux gel packs to ensure goods arrive at the desired temperature.In contrast to cold packs alone, the use of ice chests provide a thermal shield for extended transit or storage of goods within your supply chain. Whether supplies will be outside the confinement of a cooler or undergo multiple departures, these Cryolux ice chests can extend temperature regulation for many hours during transit.

 
Highly Temperature Sensitive Goods And Merchandise 


Some types of supplies are highly sensitive to temperature variations within a few degrees. Whether the goods being delivered like Gourmet food, Cheese, Seafood, Meat, Pharmaceutical products, Biological Samples etc data loggers are used to monitor any temperature variations and the data is then used to improve effectiveness of the temperature solutions where required Unlike the logging of large shipping containers housing many goods, independent data loggers can be placed on individual packages at the time of departure. Upon arrival, reports can be retrieved via a USB data connection to a computer.
 

Quality Control And Loss Prevention

The efficiency of the cold chain Solution depends on the ability to consistently deliver goods without temperature damages and prevent or reduce overall losses. Circumstances such as refrigeration equipment malfunctions and extended transit in uncontrolled temperatures can cause substantial amounts of damages and most situations the solutions are put together with sufficient allowance for transit delays.


Cryolux products are by many large corporations around the world in both simple and complex cold chain solutions for quality assurance and compliance to be achieved on a consistent basis. This decreases the potential for dead-on-arrival merchandise and maintains logistics best practices for loss prevention in your cold supply chain.

CRYOLUX COLD CHAIN QUALIFICATION & SHIPPER DESIGN

STAGE 1: REVIEW PROCESS

We highly recommend conducting a review of the client’s current cold chain as a starting point.

Cryolux analyses the whole distribution chain: current methods, operational  processes and other key elements that may impact the temperature-sensitive supply chain.  Cryolux  identify areas for potential operational improvements and cost reductions.

To achieve a validated cold chain, the solution can often present increased costs. In the review process, we identify all the potential cost savings –efficiencies and improvements – which can offset any increased costs by critiquing the entire cold chain – not just the individual pieces.

A) REPORT

We deliver a comprehensive report at the completion of the review: this contains our recommendations; key elements to be reviewed, potential risks identified and suggested actions the client can take toward achieving these improvements. Briefing for senior management may be included if requested by the client.

B) PROJECT PLAN

The review is used as the “foundation” for the development of the project plan. The project plan entails setting timelines with the client and outlining the scope of the project. Geographic locations and transit profiles will be determined, and specific destinations deemed as critical will take precedence.

Cryolux treat the review and project planning processes as critical points in the cold chain review process. Critical information is collected from the client. Cryolux use this review to meet with relevant managers and departments directly involved with the temperature supply chain. The process also provides an excellent opportunity for staff training within the company.

Cold Chain Qualification & Shipper Design

C) MATCHING SOLUTIONS TO THE CLIENT SPECIFICATION

We use the planning process to identify the possibility of using the same shippers for all temperature ranges and therefore obtain economies of scale for the client.

For example, we often use the same shippers for controlled ambient +10°C to +25°C, +2°C to +8°C shipments and frozen (-21°C or -26°C) shipments. We only vary the packing configurations to suit each temperature requirement.

Often the most economical solutions can include a combination of fully re-usable, semi re-usable and disposable packaging.

If this is the specification, we design solutions where one qualification test may be utilised for all three solutions. This provides the client with significant cost savings. In addition, Cryolux can develop a single size shipper with multiple packing configurations to meet 24 to 144-hour shipments which also offer many benefits.

STAGE 2: VALIDATION PROTOCOL

A cold chain shipper protocol is required before we may commence the critical validation process.

Essentially this will form the starting point for the shipper design, validation, and environmental chamber qualification. This validation protocol will become a tool that may be utilised for future temperature supply chain audits. The protocol is written to encompasses all products: including new products to be  released if they are to follow a similar cold chain distribution process. The development of the protocol will take approximately 4 hours, with involvement of key personnel from each department.

Key decisions need to be addressed from Quality, Operations and Distribution perspective.Cryolux  discuss the impact of each decision as well as highlight where key advantages may be gained. This stage can be conducted remotely via web conferencing and via telephone, unless travel is expressly required.

This protocol is a once only exercise and  can be utilised for future shipper sizes and products that will follow the same or similar logistics circuit.

For International projects it is important to identify similarities and group the profiles to reduce the quantity of qualification tests required, to achieves economies of scale.

STAGE 3: HEAT LOAD CALCULATION 

Utilising the cold chain protocol and review data we can calculate the heat loss from the shippers over time.In addition, Cryolux calculates the quantity of cooling energy required for cold chain products and the quantity of heating energy required for ambient products.

A) SHIPPER OPTIMISATION

Each and every company require different loadings. Cryolux  customised solutions allow the adjustment of designs of our shippers. This is achieved by calculating load size and optimising the load-to-cubic ratio. Size of the shipper is kept to a minimum, to minimise freight costs.

B) PACKING CONFIGURATIONS / TEST SAMPLES

Sample shippers for qualification are manufactured for the temperature testing and pack-out in our NATA-traceable certified environmental chambers.

The final stage of design is to develop an initial packing configuration for testing to meet the profile. It is important to ensure It works operationally for the company and all the key variables are considered. In addition, many of our validations comprise single packing configurations which suit both summer and winter transit profiles. With a single packing configuration a company has an immediate reduction in risk, improved packing time and reduction in labour costs.

STAGE 4: QUALIFICATION TESTING 

The final stage is the temperature qualification of the shipper. We test the shippers in our environmental chambers to confirm they meet the validation protocol and provide reports containing the 3 shipper tests, for each profile.

All testing is conducted with NATA certified equipment. Our quality systems reference GMP and we meet FDA Title 21 CFR Part 11 requirements.

 

STAGE 5: SHIPPER MANUFACTURING 

FROM FINAL APPROVAL AND ACCEPTANCE OF THE QUALIFICATION OUR FACTORY IS ABLE TO OFFER MULTIPLE SOLUTIONS OR FULLY RE-USABLE.

These solutions include flat-pack, minimum Reusable, disposable solutions, soft case and hard case solutions The flat pack solutions will minimise inbound freight costs.

At Cryolux, We pride ourselves in our approach, attention to detail in understanding client requirements and the most innovative solutions that in most cases exceed client expectation. 

Please feel free to contact us for any cold chain requirements using the form below.

Cryolux- Innovation is the Difference