Can Thermal Packaging Be Reused? Here’s How We Proved It with Connex 7D

By Richard Harrop, Product Director at Topa Thermal

It’s a question we hear often: “Can I reuse my thermal packaging?” The honest answer? It depends – on how you treat it. 

As pharmaceutical packaging developers, we know that understanding the stresses your design will face is key to creating solutions that perform reliably.

But in the world of pharma cold chain logistics, where time and temperature performance are critical, reuse claims have often been based solely on material specifications.

That’s surprising when you consider how components interact. Damage a thermal package and you compromise not just the physical integrity of the payload, but its thermal protection too.

A burst cool pack won’t deliver the performance it was designed for.

Our Approach: Test to the Limit

When we developed the Connex 7D parcel line, we wanted a clear, evidence-based answer to the reuse question. So we did what any responsible design team would do:
We tried to destroy what we created.

At our mechanical test lab, we subjected Connex 7D to repeated stress loops – impact, vibration, compression – and after each cycle, we re-ran thermal qualification testing. Again and again. The goal? To confirm that mechanical integrity and thermal performance remain intact through multiple uses.

The Result: Reuse Qualification Done Right

The outcome was groundbreaking: reuse qualification for thermal packaging that considers both mechanical durability and thermal reliability. For the first time, reuse isn’t just a claim – it’s proven through rigorous testing.

Why It Matters

• Confidence in Performance: ISTA 7D-qualified parcels with 120-hour-plus temperature control.
• Sustainability Without Compromise: Reduce waste while maintaining GDP compliance.
• Lower Total Cost of Ownership: Fewer disposables, more savings.

Packaging Reuse is Proven Through Rigorous Testing at Topa Institute

Want to Learn More?

If you’re exploring reusable thermal packaging or need long-duration solutions for global pharma supply chains, contact our team today. We’ll help you find the right solution for your needs.

About the Author

Richard Harrop is Product Director at Topa Thermal and a leading voice in thermal packaging innovation. With decades of experience in qualification and design, he champions solutions that deliver proven performance and sustainability.