Aeropowder to start US production of feather-based cold chain insulation

UK materials company Aeropowder has launched its PluumoPlus recycled-feather thermal insulation to US customers, with local manufacturing to begin in the first quarter of 2027 through a partnership with ColdCorr Insulated Packaging. The range includes a new 2-8°C insulated mailer for specialty pharmacy shipments, alongside dry-ice and gel-pack configurations already sold in Europe.

Why this mattersA feather-based alternative to polyurethane foam gives US pharma shippers a non-plastic option as California and Washington tighten single-use plastic packaging rules.

• PluumoPlus is made from recycled feathers sourced from the bedding and clothing industries
• US production starts Q1 2027 via manufacturing partner ColdCorr, which has sites in Arizona, Kentucky and Tennessee
• The new 2-8°C insulated mailer holds temperature for 53 hours in summer and 96 hours in winter against modified ISTA 7E profiles
• Aeropowder says the mailer can cut freight costs by up to 45% and dry-ice configurations cut dry ice use by up to 30%
• Aeropowder aims to scale to millions of units supplied into the US market annually
• California's SB 54 and Washington's expanded polystyrene ban are cited as drivers for the US launch

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