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Application of Phase Change Materials in Cold Chain Transport
thermoTab active -Enabling last mile connectivity with fuel free refrigeration.
The cold chain logistics infrastructure
Overview
Refrigerated transportation is required to carry temperature sensitive food/medicine at every step
Supply / Procurement
Precooling System Farms
(Rural Market) Manufacturer
Transport
Refrigerated Trucks
Refrigerated Railway Wagons
Refrigerated Cargo Containers
Storage
Cold Storage
Warehouses Perishable
Holding Center
Transport
Refrigerated Trucks
Refrigerated Railway Wagons
Refrigerated Cargo Containers
End Customer
Retail Terminal Markets Factory Ports Airport
Current Challenges - Temperature Controlled Transportation
Limited distribution radius without temperature control
Ideal
Current
High maintenance & operational costs of conventional cold chain logistic solutions
“In 2015, India’s infrastructure gap in reefer transport was assessed at 52,826 units; the country is estimated to have only 9000-10000 long haul reefer trucks and zero reefer containers in use.” Extracted from NCCD - AICIC study
Different F&V products require different temperature range
Current Challenges - Temperature Controlled Transportation
Spoilage due to poor or no temperature control
-18 to -20°C 2 to 8°C 15 to 25°C
“Cold-chain development must shift from the past focus on cold storage alone, towards a supply chain based approach. The cold-chain needs to function as a conduit that communicates farm produce, at the right temperature, to multiple terminal markets. This approach will be crucial for doubling of farmers income, to bring farm productivity to gainful use and to have a future ready food supply system.” – Pawanexh Kohli, NCCD
thermoTab™active – Enabling fuel free refrigeration for logistics and PLUSS in collaboration with FIC, Italy, offers an innovative solution for temperature controlled logistic
solution to enable temperature controlled transport of food and beverages.
thermoTab active PCM plates
About thermoTab active
An innovative solution for temperature controlled logistics.
Enables the transport of temperature sensitive food and beverages without any need for active diesel run refrigeration system.
Made up of two sheets of mild steel, cold formed and welded together through electrical resistance.
External surface covered with a thin layer of zinc while into the plate is the Phase Change Material.
An evaporator coil, made up of mild-steel, is positioned into the plate that allows freezing of the phase changing solution.
Segmented into two broad categories on the basis of applications: Chilled (2oC to 8oC) and Frozen (-25oC to -18oC).
Pluss® PCM
Maintains constant temperature utilizing the latent heat.
Thermal Management to increase efficiency.
Shifts peak power loads to off-peak hour.
Reliable temperature backup.
Re-usable for more than 2000 thermal cycles.
Green technology - Environment friendly.
Range and Specification
S. No Model External Dimension
(mm) Total Weight /plate
(kg) Energy Extraction / plate
(kWh)
1 Thermotab active 1250F 1190 x 485 x 54 46.5 2.03
2 Thermotab active 1370F 1290 x 690 x 49 64.5 2.54
1. Frozen (-15 to -25OC)
S. No Model External Dimension
(mm) Total Weight /plate
(kg) Energy Extraction / plate
(kWh)
1 Thermotab active 1250C 1190 x 485 x 54 39.5 1.71
2 Thermotab active 1370C 1290 x 690 x 49 55.5 2.50
2. Chilled (2 to 8OC)
Advantages of thermoTab active over conventional systems
thermoTab active System Forced Cooling (Conventional) System
• No moving parts involved throughout the operation • Continuous running of evaporator fan and compressor
• Low servicing cost • Higher servicing cost involved
• Lasts as long as the truck itself • Life of such a system is ̴ 5yrs
• No skilled personnel required • Skilled personnel required for its servicing
• Product is continuously cooled even if truck breaks down • Product safety hampered if truck breaks down
• Non polluting product- no exhaust generated • Air Pollution due to continuous exhaust
• No noise generation • High levels of noise generated
How selection is done?
Understanding the
heat load
1
Sizing the refrigeration
capacity
Selection of
thermoTab™active
plate
2
3
Performance & Temperature Validation
Disclaimer: All Trial results are obtained under standard conditions
-30
-20
-10
0
10
20
30
40
10:26:24 AM 2:31:12 PM 6:36:00 PM 10:40:48 PM
Tem
pe
ratu
re (
De
g C
)
Time
Frozen Application
Ambient Temperature Internal Temperature
0
5
10
15
20
25
30
35
40
10:26:24 AM 2:31:12 PM 6:36:00 PM 10:40:48 PM
Tem
pe
ratu
re (
De
g C
)
Time
Chilled Application
Ambient Temperature Internal Temperature
Cost Benefit Analysis
*Based on assumptions for 12 hours operation per day in TATA 407
Parameter Chilled Frozen
Payback Period (year) < 1 < 1
Annual Saving (INR lakhs) 4.2 5.1
0.0
5.0
10.0
15.0
20.0
25.0
Diesel Operated thermotab®active
Chilled
Co
st (
INR
Lak
hs)
First year cost for Chilled Application*
Initial Cost Running Cost/year
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Diesel Operated thermotab®active
Frozeen
Co
st (
INR
Lak
hs)
First year cost of Frozen Application*
Initial Cost Running Cost/year
Frozen
11lakhs 11.8 lakhs
7.7 lakhs 12 lakhs
15.8 lakhs
8.7 lakhs 13.8 lakhs
13 lakhs
Parameters Without PCM With PCM
Remarks Rs. Lacs Rs. Lacs
Initial cost
Cost of Truck 7 7 For TATA 407 Vehicle ( 8ft x 6ft x 6ft)
Total cost of PCM-Eutectic Plates to be required 1.50 5 nos. of thermoTab™ active 1250C for 2°C and 12 hours backup
Truck Body 1.5 1.50 Actual quotes from supplier and customer inputs
Diesel Refrigeration unit cost 2.5 Inputs from customer
Condensing unit for charging plates 1.75 Including installation charges as Rs. 15000
Total Capital Cost 11.00 11.75
Operating cost
Diesel Consumption for the vehicle ,Liters per hour 4 2.5 Source: Case study for refrigerated trucks & Data obtained from customer
Per Day (12 hour), Liters 48 30
Diesel Cost Per annum (12 hrs. x365 days) 11.388 7.1175
Electricity Cost per day 0.001 Rs.6 per unit x 10 units (required to charge PCM plates)
Electricity Cost per annum to charge the PCM Plates 0.219
Any other costs - Maintenance etc. 0.569 0.367 5% of the running cost
Total Running Cost per annum 11.96 7.70
Savings
Investment in Capital cost 0.75 Lacs (difference between Refrigeration system and PCM cost)
Annual Savings using PCM system per truck 4.25 Lacs (difference in their running cost)
Payback Period 3-4 months Including any other extra expenses
Sample Case Study: Cost Benefit Analysis for Chilled Variant Reefer Truck
Thank You
