“Did you hear what happened with that pharma company? They almost lost a huge shipment of insulin because of a temperature issue!”
The gossip spread quickly. Insulin, a life-saving medication for diabetes patients, is extremely sensitive to temperature changes. If it's not stored properly, it can lose its effectiveness. One major pharmaceutical company was facing a big problem with their insulin shipments, and it nearly cost them millions.
Introduction
Temperature-sensitive drugs traverse various stages of the supply chain, underscoring the importance of maintaining proper temperatures from manufacturing to end-user distribution. Regulatory bodies like the U.S. FDA and the European Medicines Agency have instituted guidelines to uphold the integrity of pharmaceuticals during storage and transportation.
Insulin, used by millions of diabetes patients, is highly temperature-sensitive. It needs to be stored and transported at a precise range between 36°F and 46°F (2°C and 8°C) to remain effective. When exposed to temperatures outside this range (whether too hot or too cold), insulin can degrade, losing its ability to regulate blood sugar levels.
Pharmaceutical companies have always struggled to ensure that insulin is kept at the correct temperature throughout its journey from the manufacturer to hospitals and pharmacies. In this case, a well-known pharmaceutical company was facing a serious cold chain failure that could have resulted in the loss of an entire shipment of insulin. If not addressed immediately, it would have meant millions of dollars in lost product and the risk of compromised patient care.
Business Case
This particular company was shipping a bulk order of insulin to hospitals and pharmacies across multiple regions. The journey involved several stages, from the company’s production facility to cold storage, onto delivery trucks, and finally to pharmacies and hospitals.
For years, the company had relied on traditional temperature-monitoring systems that required manual checks at key points in the cold chain. However, during one critical shipment, a temperature variation was detected midway through transportation. The issue was the exact time and extent of the variation were unknown.
If the insulin had been exposed to out-of-range temperatures for too long, it could have lost its potency. This left the company with two risky options. One option was, they could either discard the entire shipment, costing millions, and the other option was, they could release the insulin to patients, potentially putting lives at risk. Both options were unthinkable.
Solution - Polar Snapshot to the Rescue
Facing this urgent problem, the company turned to Polar Snapshot, a mobile app developed by SenzMate that allows workers to easily capture and track real-time temperature data throughout the cold chain. Polar Snapshot provided the perfect solution to prevent such issues in the future.
Polar Snapshot operates by enabling employees to use their smartphones to capture temperature readings at various stages of the cold chain. The app automatically logs and syncs this data to a centralized system, allowing for real-time monitoring and immediate alerts if temperatures fall outside the safe range.
The company saw an opportunity to integrate Polar Snapshot into their cold chain management system to ensure the insulin shipment was continuously monitored at every stage such as from the warehouse, through transport, to the final delivery point.
Actions Taken
1. Before integrating Polar Snapshot on a large scale, the company initiated a pilot test on a smaller shipment of insulin. Employees at different stages of the cold chain were trained to use the app to capture temperature data at critical control points such as, when loading the insulin at the warehouse, during transit, and upon delivery.
2. After the success of the test, the company implemented Polar Snapshot across their entire insulin distribution network. The mobile app was integrated into the company's existing systems, allowing them to track temperature data automatically and in real time. Employees no longer had to manually check temperatures at set intervals, everything was automated through the app.
3. The integration of Polar Snapshot meant that the company’s cold chain managers could now monitor temperature readings in real time. They set up automatic alerts, which would notify the team if the temperature exceeded or fell below the acceptable range. This feature allowed them to take immediate corrective actions, preventing product loss and ensuring the insulin remained within safe limits.
4. A training program was created to make sure all employees handling the insulin shipments, including warehouse staff, drivers, and delivery teams, were proficient in using the app. This found a smooth transition to using Polar Snapshot as a key part of their cold chain monitoring.
Results
The results of implementing Polar Snapshot were very clear.
Polar Snapshot provided complete visibility into the temperature conditions of the insulin at every stage of the cold chain. This real-time insight allowed the company to catch temperature issues early, before any damage could occur. Any deviation was reported instantly, enabling immediate action.
Thanks to the instant alerts and real-time monitoring, the company was able to avoid future temperature problems and reduce the risk of product loss. Over time, they saw a 30% decrease in lost insulin shipments due to temperature-related issues.
With Polar Snapshot, all temperature data was automatically logged and saved in the system. This made it much easier for the company to comply with regulatory requirements for temperature-sensitive products, providing detailed records for audits and inspections.
Employees no longer had to perform manual checks or record temperature data manually, which improved their efficiency and reduced human error. The automation of temperature logging freed up staff to focus on other tasks, increasing overall productivity.
Perhaps most importantly, the company was able to restore confidence in its ability to safely deliver life-saving insulin to patients. The worry of temperature deviations ruining an entire shipment was no longer hanging over their heads.