No-Compromise Cold Chains

Exploring the benefits of cold-chain-as-a-service

By Jay McHarg, CEO, AeroSafe Global

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Pharmaceutical manufacturers are adjusting to a new set of realities, from the influx of new gene- and cell-based therapies, to the expectation that therapies will be more readily available at points of care, including patients’ front doors. While that progress should be celebrated, it also poses new challenges for traditionally rigid and unreliable cold chain processes. Additionally, it underscores the urgent need for transport to become highly flexible and infinitely more dependable than current systems.

Ultimately, manufacturers have two choices when it comes to achieving greater cold chain reliability and flexibility: make or buy. Choosing to make a cold chain system can offer companies a sense of control and flexibility over the process. But it also requires significant investments in money, time and resources to develop, engineer and operate their own state-of-the-art cold-chain systems that can handle the intricacies of a thriving and constantly changing global marketplace.

On the flip side, choosing to buy into a holistic solution with a provider that specializes in cold chain logistics can create an easier way to guarantee that drugs will remain safe and effective as they’re transported to patients around the globe.

A Changing Industry

The pharmaceutical industry loses tens of billions of dollars as a result of temperature excursions, making transport one of the weakest links in many manufacturers’ supply chains.1 Despite these underwhelming statistics, the industry and its regulators can and will continue to demand zero excursions, and the technology and infrastructure are certainly there to support that.

At present, millions of shipments per year arrive at their end destination out of spec for temperature. That’s unacceptable, since excursions are likely to affect drug efficacy and patient safety, yet not entirely surprising considering the number of people and imperfect processes that can “touch” a product during transport. With advances in life sciences R&D, more manufacturers are producing temperature-sensitive, high-value biologics, and this means the risk of costly, life-threating temperature excursions will only grow.

In the last few years alone, more than half of the top 50 global drug products required cold chain (temperature controlled) handling. By 2022, the number is projected to be greater than 60 percent, with total sales approaching $150 billion. Within 10 years, it’s estimated that temperature-sensitive drugs will account for more sales than non-temperature-sensitive drugs.

Screen Shot 2019 02 27 at 9.28.53 AMCold Chain Challenges

For many manufacturers, a truly connected cold chain remains inconceivable. They may make incremental progress, from using new packaging to more efficient transport and sensors, but many still struggle for consistent, reliable performance. Regulatory requirements from the U.S. Food and Drug Administration, European Commission and other entities worldwide are certainly an important driver, but the pressure is still on the manufacturers to ensure that their products meet or exceed quality standards, are safe, and work as intended when they reach patients.

From cancer treatment to flu vaccines, exposing drugs to temperatures outside of recommended specifications during transport can have  lasting and damaging effects on manufacturers. At a minimum, they may be subject to violations and fines from the FDA, and are forced to absorb the costs of spoiled or damaged products, affecting the company’s bottom line and drawing the ire of stakeholders. Brand reputation can also be severely or permanently damaged if manufacturers cannot deliver safe products. In a worst case scenario, compromised drugs make their way to patients.

Until recently, manufacturers have had little choice but to manage the entire process themselves, from pack-out (including everything from boxes to dry ice), to shipping-lane decisions and data collection. This requires hefty upfront and ongoing investments of time and resources. And for most manufacturers, managing a complex cold chain falls outside of their core competencies, distracting them from their primary mission: savings lives.

By outsourcing complex cold chain functions to experts, manufacturers can avoid making investments in infrastructure and technology that quickly becomes outdated. Those investments are better left to third parties who are constantly refining cold chain technology and processes and can promise zero excursions and 100 percent accountability.

Defining Cold-Chain-as-a-Service

A cold chain isn’t one thing. It’s a combination of products and services that include vital links of packaging, storage, transportation and monitoring, all working in unison to ensure quality and consistency. It’s complex but necessary to accommodate product that has an equally complex composition which can be rendered dangerous or ineffective by even the slightest variation in temperature. What’s needed for an uninterrupted cold chain is seamless integration that ensures reliability and flexibility without sacrificing simplicity.

When organized in a highly integrated fashion, including easy-to-pack, reliable containers; shipping management, data analysis and more, this unbroken chain is aptly called cold-chain-as-a-service (CCaaS). Like its corollary software-as-a-service (SaaS), CCaaS is predicated on maintaining quality, safety and efficacy from development to end use. Best practices and technological innovation are perpetual and expected, accounting for the newest regulatory requirements and introduction of new drugs with even tighter cold-chain handling tolerances.

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