--- title: $500K a Year Shifting to Passive Pallets | Trans-Solutions description: A pharmaceutical manufacturer cut over $500,000 a year from international air freight by shifting temperature-sensitive shipments from active to passive pallets. image: https://trans-solutions.com/hubfs/67664138193805fa627dbd932cc9ba339c10b5bb.jpg --- [![Trans-Solutions](https://trans-solutions.com/hubfs/raw_assets/public/trans-solutions-2026/assets/ts-logo-white.svg)](https://trans-solutions.com/) [Services](https://trans-solutions.com/services) - [Freight Rate Negotiation](https://trans-solutions.com/services-freight-rate-negotiation) - [Parcel Rate Negotiation](https://trans-solutions.com/services-parcel-rate-negotiation) - [Carrier Sourcing & RFP](https://trans-solutions.com/services-carrier-sourcing-rfp) - [Vendor & TMS Selection](https://trans-solutions.com/services-vendor-tms-selection) - [Cold Chain Logistics](https://trans-solutions.com/services-cold-chain-logistics) - [Transportation Operations Audit](https://trans-solutions.com/services-transportation-audit) - [Freight Bills & Recovery](https://trans-solutions.com/services-freight-bill-audit-claims-recovery) - [Network Design](https://trans-solutions.com/services-network-design) [Case studies](https://trans-solutions.com/case-studies) How we work - [About Paul](https://trans-solutions.com/paul-brinkman) [Contact](https://trans-solutions.com/contact) [Savings Calculator](https://trans-solutions.com/savings-calculator#step1) [Book a call](https://trans-solutions.com/contact) # Over $500K a year saved shifting international air shipments from active to passive pallets Cold Chain Logistics Air & ocean Cold chain Pharmaceutical & medical devices ![Active vs passive pallets case study](https://trans-solutions.com/hubfs/67664138193805fa627dbd932cc9ba339c10b5bb.webp) CONTENTS - [Who](https://trans-solutions.com/case-studies-active-vs-passive-pallets-cold-chain#who) - [Problem](https://trans-solutions.com/case-studies-active-vs-passive-pallets-cold-chain#problem) - [What we did](https://trans-solutions.com/case-studies-active-vs-passive-pallets-cold-chain#what-we-did) - [Results](https://trans-solutions.com/case-studies-active-vs-passive-pallets-cold-chain#results) WHO ## Business model A multi-billion dollar pharmaceutical manufacturer shipping temperature-sensitive products internationally, with drug product stored in vials that has to be maintained at 2 to 8°C. ## Industry Pharmaceutical cold chain, where there is little tolerance for temperature variation and the cost of getting it wrong is the product itself. PROBLEM ## What they felt The company wanted to evaluate the potential to cut international freight costs by changing shipping methods for temperature-sensitive products, and asked Trans-solutions to recommend the best shipping method to reduce costs while ensuring product integrity. ## What we found The dominant shipping method for such products is active pallets that plug into an outlet for cooling. Envirotainer and CSafe are examples of active pallet suppliers. Passive pallets are less expensive but use PCMs and gel packs for cooling and are not practical for extended ship times. Due to the limited number of suppliers, lease costs for the units are high and the 635 kilo unit weight increases weight-based air and surface freight costs. WHAT WE DID ## Prep and analysis To determine if passive shipping systems could reliably sustain 2 to 8°C, it was necessary to analyze dozens of different factors, including all storage and transport legs and method of cooling at each building, flight and truck; time for each leg; efficacy of holding the temperature; and every cost element to ensure an accurate cost comparison. Larger-sized passive pallets are relatively new, so significant data had to be gathered from vendors on packing methods and materials. ## Execution Trans-solutions determined that, for the specific lane examined, annual savings of $203,000 was possible with a shift from active to passive pallets for a percent of shipments. ## We left them a rule, not a recommendation The analysis clearly indicated the criteria required, product type, origin, airport used and transit time, to trigger use of a passive pallet option. That means the client can apply the decision themselves on lanes we never looked at. RESULTS ## What they got **Over $500,000 a year on international air, with 100% temperature control maintained** Applied across this company's global supply chain, the strategy would save over $500,000 annually for just international air shipments, with 100% temperature control maintained. The durable value is the methodology. They hold a tested trigger for when passive is safe and when it is not, lane by lane, rather than a one-time answer for one lane. Related case studies - [![Pharmaceutical sample distribution case study](https://trans-solutions.com/hubfs/15a34acf6f6918670302d7a1377bd58bd036d33cc-1.webp) Over $1M a year saved on PDMA-compliant sample distribution →](https://trans-solutions.com/case-studies-pharmaceutical-sample-distribution) - [![Pharmaceutical asset tracking case study](https://trans-solutions.com/hubfs/4f2e52ea62d02b4c35e2906ed279f708694f5757.webp) A 15% to 20% smaller freezer tank fleet for Genentech →](https://trans-solutions.com/case-studies-pharmaceutical-asset-temperature-tracking) Related services - [Cold Chain Logistics →](https://trans-solutions.com/services-cold-chain-logistics) - [Freight Rate Negotiation →](https://trans-solutions.com/services-freight-rate-negotiation) ![](https://trans-solutions.com/hubfs/raw_assets/public/trans-solutions-2026/assets/cta-bg.jpg) ## How much are you leaving on the table? Instant estimate based on data from 600+ clients we have helped Calculate your savings potential ### Ready to get started? [Book a call with Paul](https://trans-solutions.com/contact) ![Trans-Solutions](https://trans-solutions.com/hubfs/raw_assets/public/trans-solutions-2026/assets/ts-logo-white.svg) Trans-Solutions, Inc. Independent transportation consultants since 1997. We are not affiliated with, compensated by, or acting as an agent for any carrier. [![](https://trans-solutions.com/hubfs/raw_assets/public/trans-solutions-2026/assets/linkedin.svg)](https://www.linkedin.com/company/trans-solutions-consulting/) © 2026 Trans-Solutions, Inc., Ladera Ranch HQ