London Daily

Focus on the big picture.
Wednesday, Aug 20, 2025

The mind-boggling logistics of transporting one of the most important vaccines in history

The mind-boggling logistics of transporting one of the most important vaccines in history

Two coronavirus vaccines are in line to be authorized for emergency use in the United States, and a massive transportation network is standing at the ready once they receive government clearance.

The delicate, mind-boggling logistics of distributing the vaccines will be crucial. The challenges of moving millions of doses — over thousands of miles and under strict temperature specifications — are enormous.

Here's what we know about how vaccines will be physically transported from drug manufacturers to medical facilities around the world.

The first 24 hours


Within 24 hours of an emergency use authorization from the US Food and Drug Administration, manufacturers and shippers are prepared to activate the delivery chain — a complex system of warehouses, trucks, planes, and, ultimately, delivery to the site where shots are administered.

The planning, dry runs, and stockpiling is already underway.

"We're moving all of the needles, the syringes, the other parts and pieces to include the alcohol wipes and necessary [supplies] in order to administer these vaccines," said Lt. Gen. Paul Ostrowski, the director of supply, production and distribution for Operation Warp Speed, the US government's effort to develop a Covid-19 vaccine.

Pfizer (PFE) is stockpiling an undisclosed number of vaccine doses in Kalamazoo, Michigan.

Once the vaccine is authorized, Pfizer doses will be packed into trucks and much of it sent to airports to be loaded onto planes.

The distribution of Moderna (MRNA) vaccines is set to be handled by the medical supply company McKesson.

"It's a really quick process, simply putting together the packages on dry ice and shipping them out," Ostrowski said of the Pfizer vaccine.

Trucks will ferry the vaccines to planes that will deliver them around the country.

Staying cool


There are two ways to keep the vaccines cold in transit: Active cooling containers and passive cooling containers.

Active containers use batteries and a cooling system to keep the contents cold. The containers are charged while they're on the ground, then the battery system kicks in while they're in transit. Temperature-sensing devices in the actively cooled containers also have the capability send an alert if the temperature deviates -- even slightly, by a quarter of a degree — outside of the approved range.

Passive containers are packed with ice packs or dry ice, depending on how cold it needs to be and how long the trip is. Typically, if the route has more than one stop, these containers will move to cold storage facilities between legs of the trip.

Dry ice can pose its own risk in large quantities. Regulators typically have strict weight limits for dry ice on flights because it releases carbon carbon that "can cause aircrew incapacitation." But airlines say regulators are easing those restrictions slightly for vaccine distribution.

UPS said it is producing 24,000 pounds of dry ice each day, and is supplying all of the dry ice used by Operation Warp Speed.

"We will ship a box of 40 pounds of dry ice to all Pfizer dosing locations a day after the vaccine arrives," UPS said.

The delicate process of keeping the vaccines cold continues once the planes land.

Flying the vaccines


Thousands of flights will be needed to carry distribute the vaccines around the world - some 8,000, according to the International Air Transport Association.

American Airlines (AAL) says its widebody 787 jetliners can carry about a half-million vaccine doses.

American began in mid-November running test flights between South America and Miami, where it will bring vaccine shipments into the US. It said the test flights "simulate the conditions required for the COVID-19 vaccine to stress test the thermal packaging and operational handling process that will ultimately ensure it remains stable as it moves across the globe."

The planes used to transport the vaccine will be a mix of cargo jets and passenger planes. In some cases the passenger flights will be cargo-only, but it's entirely possible that vaccines will be beneath your feet on your next flight.

"The quantities of vaccine or we envisage moving will be enormous, particularly if we get multiple vaccines approved in a short space of time," said Roger Samways, the vice president of cargo sales at American Airlines. "I think fairly quickly we could reach a situation where actually most of the planes out there, carry vaccines in one shape or form."

American Airlines has a 25,000 square-foot warehouse in Philadelphia that it uses exclusively for pharmaceutical shipments. The facility is capable of simultaneously charging 50 massive, actively cooled containers, as well as storage bays with four levels of refrigeration ranging from just above freezing to minus-20 degrees Celsius. Each of the refrigerated compartments — large enough to drive several vehicles and pallets into -- contain dual cooling systems and a generator in case of power failure.

United Airlines has a major refrigerated storage facility at Dulles airport outside of Washington that handles pharmaceutical and other shipments that need to remain chilled.

While these facilities play a critical role in the chain, the goal is to limit the amount of time shipments spend there.

"Our job is to move things as quickly as possible maintaining the temperature while it's in our possession," said Samways.

On the ground


Once the planes land, truckers will be responsible for the vaccines' final legs. FedEx and UPS will be involved in the ground distribution effort.

UPS (UPS) said it is overseeing the "a highly coordinated set of movements" from its around-the-clock command center in Louisville, Kentucky, tracking the shipments and remotely monitoring the temperature of each package. UPS says its command center software can anticipate delivery interruptions.

The suitcase-sized containers carrying the Pfizer vaccine that will soon leave the factory will be packed with dry ice produced by UPS.

FedEx (FDX) says it has more than 90 cold storage facilities worldwide to aid in the keeping the Pfizer vaccine at its required super-cold transport and storage temperature. FedEx says it currently transports roughly a half million shipments containing dry ice each month.

Vaccines "will be delivered directly to the point of vaccination, if specified by the jurisdiction," according to a briefing transcript from the White House.

The Federal Motor Carrier Safety Administration, which regulates trucking in the US, said it is suspending so-called hours-of-service rules that regulate how long truckers may drive.

The vaccine containers contain GPS tracking so that the location of the package is known at all times. "These are becoming more and more prominent in the industry so customers can tell exactly where a shipment is," said Samways.

Once the vaccine is in the hands of state and local officials, the next steps in distribution are up to them.

Newsletter

Related Articles

0:00
0:00
Close
Trump Called Viktor Orbán: "Why Are You Using the Veto"
Horror in the Skies: Plane Engine Exploded, Passengers Sent Farewell Messages
MSNBC Rebrands as MS NOW Amid Comcast’s Cable Spin-Off
AI in Policing: Draft One Helps Speed Up Reports but Raises Legal and Ethical Concerns
Shame in Norway: Crown Princess’s Son Accused of Four Rapes
Apple Begins Simultaneous iPhone 17 Production in India and China
A Robot to Give Birth: The Chinese Announcement That Shakes the World
Finnish MP Dies by Suicide in Parliament Building
Outrage in the Tennis World After Jannik Sinner’s Withdrawal Storm
William and Kate Are Moving House – and the New Neighbors Were Evicted
Class Action Lawsuit Against Volkswagen: Steering Wheel Switches Cause Accidents
Taylor Swift on the Way to the Super Bowl? All the Clues Stirring Up Fans
Dogfights in the Skies: Airbus on Track to Overtake Boeing and Claim Aviation Supremacy
Tim Cook Promises an AI Revolution at Apple: "One of the Most Significant Technologies of Our Generation"
Apple Expands Social Media Presence in China With RedNote Account Ahead of iPhone 17 Launch
Are AI Data Centres the Infrastructure of the Future or the Next Crisis?
Cambridge Dictionary Adds 'Skibidi,' 'Delulu,' and 'Tradwife' Amid Surge of Online Slang
Bill Barr Testifies No Evidence Implicated Trump in Epstein Case; DOJ Set to Release Records
Zelenskyy Returns to White House Flanked by European Allies as Trump Pressures Land-Swap Deal with Putin
The CEO Who Replaced 80% of Employees for the AI Revolution: "I Would Do It Again"
Emails Worth Billions: How Airlines Generate Huge Profits
Character.ai Bets on Future of AI Companionship
China Ramps Up Tax Crackdown on Overseas Investments
Japanese Office Furniture Maker Expands into Bomb Shelter Market
Intel Shares Surge on Possible U.S. Government Investment
Hurricane Erin Threatens U.S. East Coast with Dangerous Surf
EU Blocks Trade Statement Over Digital Rule Dispute
EU Sends Record Aid as Spain Battles Wildfires
JPMorgan Plans New Canary Wharf Tower
Zelenskyy and his allies say they will press Trump on security guarantees
Beijing is moving into gold and other assets, diversifying away from the dollar
Escalating Clashes in Serbia as Anti-Government Protests Spread Nationwide
The Drought in Britain and the Strange Request from the Government to Delete Old Emails
Category 5 Hurricane in the Caribbean: 'Catastrophic Storm' with Winds of 255 km/h
"No, Thanks": The Mathematical Genius Who Turned Down 1.5 Billion Dollars from Zuckerberg
The surprising hero, the ugly incident, and the criticism despite victory: "Liverpool’s defense exposed in full"
Digital Humans Move Beyond Sci-Fi: From Virtual DJs to AI Customer Agents
YouTube will start using AI to guess your age. If it’s wrong, you’ll have to prove it
Jellyfish Swarm Triggers Shutdown at Gravelines Nuclear Power Station in Northern France
OpenAI’s ‘PhD-Level’ ChatGPT 5 Stumbles, Struggles to Even Label a Map
Zelenskyy to Visit Washington after Trump–Putin Summit Yields No Agreement
High-Stakes Trump-Putin Summit on Ukraine Underway in Alaska
The World Economic Forum has cleared Klaus Schwab of “material wrongdoing” after a law firm conducted a review into potential misconduct of the institution’s founder
The Mystery Captivating the Internet: Where Has the Social Media Star Gone?
Man Who Threw Sandwich at Federal Agents in Washington Charged with Assault – Identified as Justice Department Employee
A Computer That Listens, Sees, and Acts: What to Expect from Windows 12
Iranian Protection Offers Chinese Vehicle Shipments a Cost Advantage over Japanese and Korean Makers
UK has added India to a list of countries whose nationals, convicted of crimes, will face immediate deportation without the option to appeal from within the UK
Southwest Airlines Apologizes After 'Accidentally Forgetting' Two Blind Passengers at New Orleans Airport and Faces Criticism Over Poor Service for Passengers with Disabilities
Russian Forces Advance on Donetsk Front, Cutting Key Supply Routes Near Pokrovsk
×