Aeropowder, a UK-based sustainable materials company currently operating in Europe, has launched its patented PluumoPlus thermal insulation products to U.S. customers, with local production through a partnership with ColdCorr Insulated Packaging beginning in Q1 2027. The launch includes deep-frozen and refrigerated solutions, as well as the new PluumoPlus 2-8°C Insulated Mailer designed for the U.S. specialty pharmacy market.

Demand for temperature-controlled healthcare logistics in the U.S. is growing fast, with specialty medicines accounting for more than half of U.S. medicine spending, according to the IQVIA Institute. U.S. pharmacies dispensed an estimated $293 billion of specialty drugs in 2025, up nearly 10% on 2024, according to the Drug Channels Institute. Many of these therapies ship to patients’ homes or clinics, so shippers face rising freight costs and pressure to cut plastic waste.

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

From feathers to insulation: recycled feathers (bottom) and the PluumoPlus material engineered from them (top).

The PluumoPlus Mailer puts this performance to work. The company has qualified the mailer to maintain 2-8°C for 53 hours in a summer configuration and for 96 hours in a winter configuration against modified International Safe Transit Association (ISTA) 7E temperature profiles. These extended durations offer up to 45% savings in freight costs, either through smaller volumetric shipping or by allowing shippers to move from air to ground freight.

“The healthcare supply chain needs solutions that perform better and are more sustainable, and that’s exactly what PluumoPlus delivers,” said Dr. Ryan Robinson, CEO and Founder of Aeropowder. “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.”

ColdCorr, an established cold chain packaging manufacturer with locations in Arizona, Kentucky and Tennessee, will serve as the U.S. manufacturing partner for PluumoPlus to facilitate the local production of the product, and has the capability to deploy significant volumes into the market.

“I’ve never seen performance like PluumoPlus from any other natural material,” said Chris Poore, director at ColdCorr Insulated Packaging. “We are excited to support bringing PluumoPlus to customers across the U.S.”

Trials and testing are underway with select U.S. pharmacies and life science companies ahead of local production in Q1 2027. Aeropowder intends to scale PluumoPlus to millions of units supplied into the U.S. market annually, establishing it as the new standard for shippers who want premium thermal performance without single-use plastic foams.