Employees in northern parts of the country are beginning to brace themselves for working in the cold, whether it’s outside the building or inside near open doors and loading docks. Even in warmer regions, however, cold stress is a year-round reality for workers in food processing or other refrigerated areas.

Bundling up in thick, heavy layers may seem like the best solution, but it’s not. For a look at innovations and best practices in cold-weather wear for industrial applications, we spoke to Nick Reaves, product sales manager for workwear in North America at PIP, and Nora Kirby, PIP’s national account manager. Here’s what they had to say.

The Right Protection for Cold-Weather Environments

Not all winter wear is created equal. PIP, for one, offers a wide range of garments tested and rated for certain temperature zones, from above freezing to minus 51 F. This gives employers options to find the right temperature rating for particular applications.

“A lot of people will say, ‘Hey, we’ve got guys in cold coolers. We need a minus-51 certification,’” Reaves says. “In reality, they’re sitting in minus 10 or above. So, that minus 51 is overkill.”

Having more insulation than you need can be problematic, he explains.

“People think that they have to have this heavy jacket and bib on, and then they continue to layer underneath it—sweatshirt, sweatpants, long johns—thinking that they need it to keep warm,” he says. “When you start layering, you’re adding additional weight and fatigue and sweating. It doesn’t allow your body to breathe and moisture-wick because you have so many layers on underneath.”

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The Fatigue Factor: When Warmth Is a Burden

To get workwear certified for cold environments, many garment makers add heavy liners to achieve warmth. This creates one of the biggest challenges for employees, Reaves says.

“Insulation normally adds a tremendous amount of bulk to the inside of the garment,” he explains. “If the body is carrying 15 to 20 extra pounds, you’re going to fatigue, and in turn you’re going to sweat. And when you get into those cold work environments with a wet body, that’s where hypothermia takes place.”

Instead, PIP uses an innovative liner—Sorona Aura from DuPont—that is lightweight and effective.

“When you touch and feel this garment, it’s got some weight behind it, obviously,” Reaves says. “But when you put the garment on, it just sits on the body differently, and it holds in body heat, which gives you warmth.”

Fit, Flexibility and Function: Advances in Cold-Weather PPE Design

The Occupational Safety and Health Administration revised the standard for personal protective equipment (PPE) in construction in 2025, requiring employers to make sure that PPE fits properly. The rule highlights the importance of a good fit in other industries, too.

“If it’s not the right fit,” Reaves says, “then you open yourself up to snags or pulls.”

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PIP’s innovative liner, besides providing warmth, allows for stretch, flexibility and movement. “There are no constraints when you’re moving, bending, getting up and down stairs, whatever it may be,” he says. “The garment is moving with the body.”

The outer shell, made of ripstop, also allows for stretch. Plus, the shell is durable and helps knock down wind. “It has a water repellence, almost like a rain jacket, that keeps water from getting inside the garment, which would be a danger zone in cold temperatures,” Reaves says.

Smart Layering and Convertible Solutions

In environments where temperatures change considerably throughout the day, or where workers go from warmer to colder areas and vice versa, smart layering comes into play. The ability to take off or add layers can keep workers comfortable and safe.

“We have a 5-in-1 jacket and a 7-in-1 jacket,” Reaves says. “Those layers are critical depending on which way you’re going, colder or hotter.”

Kirby talks more about this type of convertible clothing: “There is a liner, a jacket, another liner. If you’re going from an incredibly cold area to a less cold area, you’ll take out an outer layer, or you’ll take out the inner lining.”

Regardless of the garment, when you’re changing temperatures, Reaves recommends an acclimation period to get your body used to the new area. “Because if you go from 70 degrees to minus 51 and you hit the ground running, it could be a big shock to your body initially,” he says. “It’s better to give your body five to 10 minutes to adjust.”

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What’s Next: Cold-Weather Safety Innovation and Listening to the Worker

Innovative cold-weather products are the result of listening to end users and delivering products they’re asking for. At PIP, “we’re pushing the envelope lighter—as light as we can go,” Reaves says. “It’s all about the weight of the garment.”

This pursuit has led to a new partnership with Gore-Tex to develop a “lighter-weight, moisture-wicking fabric that is unique to the market,” he says.

In addition to fabric technology, workers are looking for more athletic cuts, Reaves adds, “primarily driven by the younger generation that’s coming into the workforce.”

Kirby illustrates the importance of innovation at the company. “Our brand name is PIP, which is Protective Industrial Products. But we like to say it’s people, innovation and products,” she says.

“We still need to meet their expectations and their requirements in the field,” she adds, “but if we can make them more comfortable while they’re doing their job, they’re going to stay safer.”