DECEMBER 12, 2025

Bracing for the Polar Vortex: What Midwestern Shippers Need to Know & How to Protect Temperature-Sensitive Products

As the Midwest prepares for another powerful polar vortex – bringing sub-zero temperatures, high winds, and hazardous travel conditions -Illinois manufacturers, distributors, pharmacies, and healthcare providers are already feeling the pressure. Extreme cold doesn’t just disrupt operations; it dramatically increases risk for temperature-sensitive shipments.

Whether you’re handling pharmaceuticals, specialty biologics, clinical supplies, vaccines, diagnostics, or direct-to-patient therapies, severe winter weather can become your biggest supply chain variable. But with the right thermal packaging strategy, it doesn’t have to be.

Below are ThermoSafe’s top cold-weather shipping practices to help keep products protected, lanes consistent, and patients safe through the storm.

Why Polar Vortex Conditions Are Especially Challenging

A polar vortex brings more than a temperature drop – it creates inconsistent, unpredictable environmental exposure that can rapidly damage temperature-sensitive goods.

Key risks include:

• Prolonged exposure to extreme cold – risking medicine efficacy and failures of temperature sensitive products
• More time spent on loading docks due to driver delays
• Increased airport and ground-hub dwell times for air cargo
• Risk of cold temperature excursion for products intended for controlled ambient (15–25°C) or refrigerated ranges (2–8°C)

The stakes rise even higher for GLP-1 therapies, specialty injectables, cell & gene materials, and clinical trial shipments, where stability windows can be tight and excursions costly.

Ask yourself, given the extreme conditions of a polar vortex, should I refrain from shipping?
If your answer is No, see the tips below:

ThermoSafe’s Winter-Weather Packaging Tips

1. Select Packaging with Higher Insulation Properties

During polar vortex conditions, small fluctuations matter.

Consider solutions with:

1. Longer qualified durations to handle unpredictable dwell times
2. Thicker insulation (EPS, PUR, or VIP)
3. Higher R-value materials that maintain internal temperatures despite extreme cold

Your best bet is to use longer qualified duration shippers. Using packaging with thicker insulation or higher R-value materials could help, but it could also trap too much cold air in the system causing a cold excursion. When a 48-hour or 72-hour shipment quickly becomes a 96-hour shipment – that extra cold can build up inside.

2. Avoid “Protection Only” Controls for Freezing-Sensitive Products

If your product must stay above freezing, use packaging that actively prevents overcooling.

Smart strategies:

• Pre-condition gel packs to +20°C (room temp) for controlled ambient shipments
• Select systems qualified against cold weather conditions representative of your shipments
• Avoid shipping with frozen gel packs unless the lane demands it

In extreme cold, pack-outs must be intentional, not generic.

3. Prepare for Extended Transit and Build in Safety Margins

Weather disruptions can easily add:

• Extra hours on the dock
• Rerouted truck lanes
• Additional hub time during peak congestion
• Customized last-mile holds

Evaluate your lane risk:

4. Review Your Product Stability Data

Many teams underestimate the risk of freezing during winter.

Products that tolerate heat excursions don’t always tolerate cold ones.

Confirm:

• Minimum allowable exposure temperature
• Lowest validated stability threshold
• Freeze-thaw sensitivity
• Special handling instructions

Your packaging strategy should always match the product’s lowest point of failure.

5. Build Out Your Winter SOPs Now

A strong winter preparedness plan includes:

• Updated pack-out instructions for cold seasons
• Standardized packaging by lane and risk level
• Carrier-specific handling requirements
• Escalation procedures for excursions
• Communication templates for patient services and clinical teams

If you don’t have documented winter shipping SOPs, the polar vortex is your perfect prompt.

ThermoSafe’s Take: Be Prepared, Not Reactive

The polar vortex is a reminder of something ThermoSafe has championed for decades:
Thermal protection isn’t seasonal – it’s strategic.

By strengthening your packaging plan now, you can:

• Reduce product loss
• Prevent costly reshipments
• Maintain patient continuity
• Keep operations smooth despite severe weather
• Protect brand trust when customers need reliability most

Our team is ready to help you navigate winter challenges with data-driven, qualified packaging solutions built to perform under extreme conditions.

Need Help Choosing the Right Winter Packaging?

ThermoSafe experts can recommend solutions based on:

• Product profile
• Lane conditions
• Transit time
• Stability data
• Budget and scale

Reach out to your ThermoSafe representative to prepare your cold-weather shipping strategy today.
Or Contact us here.

Stay warm. Stay safe. Stay in control.
ThermoSafe – Protection You Can Trust in Every Season.