Introduction

COTESA, a trusted manufacturer of high-performance composite components for the aerospace and transportation industries, was selected as a key development partner by a European company pioneering a new generation of sustainable air cargo containers. This customer set out to revolutionize cold chain logistics with a lightweight, energy-efficient, and long-lasting air freight solution designed specifically for pharmaceutical transport.

With a shared commitment to technical excellence and sustainability, COTESA helped bring this breakthrough concept to life through the design and production of highly specialized composite parts.

Challenge

The client faced a complex engineering challenge: develop an active temperature-controlled air cargo container that met the strict requirements of global pharmaceutical transport while also achieving major reductions in weight and emissions.

Key goals included:

• Significantly lowering container weight to reduce fuel consumption during air transport
• Maintaining durability and strength for repeated handling and international shipping
• Seamlessly integrating advanced electronics and cooling systems
• Meeting sustainability benchmarks, including carbon footprint reduction

The container required tailor-made structural components that offered exceptional performance under stringent weight and sustainability constraints.

Solution

Leveraging decades of aerospace composite experience, COTESA collaborated closely with the client’s engineering team to:

• Design and manufacture custom composite structures optimized for weight savings without compromising mechanical integrity
• Apply precision molding and bonding techniques to accommodate built-in technology while maintaining structural performance
• Engineer components for high-volume manufacturability, ensuring scalability for commercial production
• Utilize environmentally responsible processes by creating a part 40% lighter than competitors, emitting less CO2

COTESA’s solutions played a critical role in realizing a container that not only met technical expectations but also raised the standard for sustainable design in air freight.

Conclusion

This successful partnership exemplifies how COTESA’s advanced composite capabilities can help forward-thinking companies transform their industries. By delivering lightweight, durable, and sustainable components, COTESA contributed to a product that is redefining efficiency in cold chain logistics.

Today, the client’s innovative air cargo container is in use across global supply chains—supported by COTESA’s commitment to engineering excellence and environmental stewardship.