Why Aeropowder Launched Feather-Based Cold Chain Packaging In the U.S.

Aeropowder, a UK-based sustainable materials company, has launched its PluumoPlus thermal packaging line to U.S. customers, with local manufacturing set to begin in Q1 2027 through a partnership with ColdCorr Insulated Packaging, the company announced.¹ The launch includes a new 2-8°C insulated mailer designed for the U.S. specialty pharmacy market.

Aeropowder, which currently operates in Europe, said PluumoPlus products are already supplied to European customers including GLP-1 distributors and clinical logistics companies. The U.S. rollout makes its deep-frozen and refrigerated configurations available to American shippers for the first time, alongside the new mailer.

“The healthcare supply chain needs solutions that perform better and are more sustainable, and that’s exactly what PluumoPlus delivers,” said Ryan Robinson, Ph.D., Aeropowder’s CEO and founder.¹ “We are keen to work with life science companies, logistics providers and packaging companies in the U.S. who need high performance without compromising on sustainability.”

What Is PluumoPlus and How Does the Mailer Perform?

PluumoPlus is an engineered insulation material made from recycled feathers. Aeropowder says its thermal performance is up to 30% better than current natural alternatives and competes with high-end polyurethane foam.¹

The new U.S. portfolio includes three product lines:

• PluumoPlus 2-8°C Insulated Mailer: Qualified by the company to maintain 2-8°C for 53 hours in a summer configuration and 96 hours in a winter configuration against modified International Safe Transit Association (ISTA) 7E temperature profiles.
• Dry Ice configurations: Deep-frozen solutions that Aeropowder says have reduced dry ice requirements by up to 30% compared with other natural materials.
• Gel Pack configurations: Refrigerated solutions currently supplied to European customers.

According to Aeropowder, the mailer’s extended durations can deliver up to 45% savings in freight costs, either through smaller volumetric shipping or by allowing shippers to move from air to ground transport.¹

How Will PluumoPlus Reach U.S. Customers?

ColdCorr, a cold chain packaging manufacturer with locations in Arizona, Kentucky and Tennessee, will produce PluumoPlus locally for the U.S. market.¹

“There is a clear gap in the market for a high-performance sustainable solution that consistently delivers extended performance under demanding conditions, and PluumoPlus does exactly that,” said Chris Poore, director at ColdCorr Insulated Packaging, in a press release.¹

Jason Johnson, chief commercial officer at Aeropowder, said trials and testing are underway with select U.S. pharmacies and life science companies ahead of the Q1 2027 production start. The company said it intends to scale PluumoPlus to millions of units supplied into the U.S. market annually.¹

Why Does the Launch Matter for Specialty and Direct-to-Patient Shipping?

Aeropowder frames the launch around rising U.S. demand for temperature-controlled healthcare logistics, driven by biologics, cell and gene therapies and direct-to-patient delivery. By one estimate, U.S. pharmacies dispensed $293 billion in specialty drugs in 2025, up nearly 10% from 2024.²

Broader spending data point in the same direction. U.S. net medicine spending rose 10.6% in 2025 to $606 billion, according to the IQVIA Institute.³ IQVIA expects an average of 50 to 55 new innovative medicines to launch annually over the next five years, including therapies in oncology, immunology and other specialty areas. Many specialty therapies ship directly to patients’ homes or clinics, according to Aeropowder, which ties the company’s freight-savings and plastic-reduction claims to a growing share of the U.S. market.¹

Shippers also face state-level pressure on plastic packaging, such as California’s SB 54, which includes aims for a 25% cut in single-use plastic packaging, and Washington’s ban on the sale of several expanded polystyrene products.¹ Pharmaceutical Commerce has previously examined how shipping lanes and transit duration shape cold chain packaging selection and how GLP-1 volume is stress-testing the pharma cold chain.

What Is Aeropowder’s Goal for PluumoPlus in the U.S.?

Aeropowder said it aims to establish PluumoPlus as a standard for shippers seeking premium thermal performance beyond existing natural materials, without relying on single-use plastic foams.¹ The company enters the U.S. market as specialty dispensing grows and states including California and Washington tighten restrictions on single-use plastic packaging, positioning recycled-feather insulation as an alternative to the plastic foams now facing those restrictions.

References

1. Aeropowder. “Aeropowder Launches Feather-Based Brand ‘PluumoPlus’ for Thermal Packaging in U.S.” Emailed press release. October 2026.
2. Fein, Adam J. “The Top 15 Specialty Pharmacies of 2025: PBM-Affiliated Pharmacies Dominate While Health Systems and Independents Gain Ground.” Drug Channels. April 21, 2026. https://www.drugchannels.net/2026/04/the-top-15-specialty-pharmacies-of-2025.html
3. IQVIA Institute for Human Data Science. U.S. Medicine Use Trends 2026: Increased Use and Spending Amid Access and Cost Pressures. April 28, 2026. Accessed Oct. 13, 2026. https://www.iqvia.com/insights/the-iqvia-institute/reports-and-publications/reports/us-medicine-use-trends-2026