Guide to Active and Passive Packaging

9 March 2026 6 Mins Read

Temperature‑controlled logistics involves storing, transporting, and delivering temperature‑sensitive items in a controlled environment to keep them at a consistent temperature from packing to arrival. This cold chain process is essential for products like food, fresh flowers, perishable goods, pharmaceuticals, and medical materials, as any temperature change can reduce their quality or even cause serious health risks.

To prevent this, cold chain couriers typically keep shipments between 2ºC and 8ºC, while manufacturers must ensure everyone in the supply chain follows these requirements. Key points where temperature deviations can happen include storage in the warehouse, the route from the manufacturer to the shipper, loading and unloading, and the actual transit. ¹

As temperature control is critical, the choice between different packaging solutions also plays an important role.

Active vs Passive packaging

Passive containers use insulation and electronics to maintain the temperature within the box for a short period of time. Thermostatic regulation is not fixed, and it uses a finite amount of pre-conditioned coolants like chilled or frozen gel packs, phase change materials and dry ice.²

Strengths ³	Weaknesses ³
With no powered components, there’s no risk of mechanical of power failures Equipment can be reused or disposed Lower tare rate, lower transport cost Modern materials offer better thermal protection at the same weight and are more environmentally friendly	Might require prior temperature preconditioning for thermal stability Some refrigerants are restricted in airfreights Multiple components required, necessitates storage capacity Easily affected by external environmental conditions and temperature extremes

Active containers can retain specific temperature ranges with a lower risk of deviations. They have a built-in heating or refrigeration unit and can also utilise dry ice as a coolant to maintain temperatures. In case of temperature fluctuations, alarms will be triggered, and relevant personnel will be alerted. They are usually much larger than passive containers, alongside being able to be locked and never opened during transport.²

Strengths ³	Weaknesses ³
Active units can be kept in standard, non-temperature controlled warehouses as long as they are plugged into a power source Active units can be leased worldwide. RKN and RLP units can be moved with forklifts for easy handling Loading/offloading and temperature-setting via control panel are straightforward processes	Not all networks and aircrafts can transport active containers Heavier container tare weight, higher shipping costs Units cannot be purchased, users must pay for leasing, pickup and return charges Containers require plug-in during transit to recharge batteries and maintain safe operation

How to choose the right packaging?

Factor	Passive Packaging	Active Packaging
Product Space Requirement⁴	Space is limited Payload efficiency is important Need to minimize dimensional weight and maximize product per shipment	Space is flexible Extra container volume is acceptable Product is high‑value and precision is prioritized over space
Shipment Routing⁵	Route is direct and predictable Low risk of delays Controlled handling environment end‑to‑end	Route involves multiple stops High risk of delays Lane has history of excursions or rehandling
Destination Storage Capability ⁶	Facilities have limited infrastructure and no power Simple delivery required	Destination can handle recharging Staff trained in active system handling Return logistics can be managed reliably
Cost & Return Logistics⁶	Budget-sensitive shipments Avoiding return fees is a priority	High-value goods justify higher packaging cost
Duration of Shipment ⁷	Short to medium duration routes	Long-duration routes

By understanding the differences between various packaging types and your own shipping requirements, moving temperature sensitive goods will no longer be a hassle. With DHL Express, your shipments move seamlessly across international borders. Every item entrusted to us is supported by real‑time tracking, giving you full transparency and confidence at every stage of the journey.