Smart Cooling System for Milk Transportation in

Rural Areas
Tankiso A. Komako1, Ashleigh K. Townsend1, Immanuel N. Jiya2 and Rupert Gouws1
1
School of Electrical, Electronic and Computer Engineering, North West University
Potchefstroom 2520, South Africa
2
Department of Engineering and Science, University of Agder,
Grimstad 4879, Norway
ashleighktownsend2@gmail.com
2021 IEEE International IOT, Electronics and Mechatronics Conference (IEMTRONICS) | 978-1-6654-4067-7/21/$31.00 ©2021 IEEE | DOI: 10.1109/IEMTRONICS52119.2021.9422554

Abstract—In the dairy industry, road milk tankers
transport milk from one location to another. The milk inside
the tanker needs to be kept between 3-5 ℃ to ensure that the
quality of milk is always preserved. The tanker needs to be
kept running at all time with the case of sufficient energy
being continuously supplied to the cooling unit. The source of
energy normally used for this application is a typical
generator which needs fuel to operate. This is expensive and
is not environmentally friendly. To address this problem,
generator as a source of energy needs to be replaced by solar
energy to lower the costs associated with cooling of the tanker.
In this research a small scale solar powered intelligent cooling
system was developed. This system was designed to make use
of thermoelectric cooler as a viable cooling unit and operating
it intelligently with a programmable logic controller. The
system was designed in a way that it can also display the
volume of milk inside the tanker and the system power
consumption.
Keywords—PLC, thermoelectric cooler, milk tanker, milk
cooling, TECM
I. INTRODUCTION
Road milk tankers, transport raw milk from dairy farms
to dairy processing factories where the milk is processed and
utilized to produce dairy products like cheese, yoghurt etc.
[1]. To ensure that the quality of the milk from milked cows
is maintained during transportation, the temperature of the
milk is kept between 3-5 °C [2]. This implies that the milk
tank, during transportation, needs to be kept running by
ensuring that sufficient charge is provided to the cooling
unit of the tank. Road milk tank trucks make use of fuel-
based energy sources like DC generator to cool down and
control the temperature of the milk during transportation.
The fuel-based energy machine is usually kept always
running to provide sufficient charge to the cooling unit. The
process to maintain the temperature of the milk is costly due
to the fuel being used as a source of energy [3].
Rapid increase in price for fuel can have devastating
effects on the freight management companies, particularly,
road milk trucks. The fuel price increase can also decrease
the profit that dairy processing plants make [4]. The use of
renewable energy sources could help reduce the high fuel
costs associated with cooling of the milk tank. The petrol
cost associated with the cooling of the milk tank is high and
this causes milk trucking/logistics companies not to make
maximum profit due to petrol expenses. The fluctuation of
petrol price constantly has evolving effects on the milk price
rates [5]. The petrol as a source of energy is not
environmentally free, and it contributes to global warming.
Environmentally friendly and renewable energy powered
intelligent milk tanks need to be developed in this case to
lower the fuel costs and fuel related global warming effects,
associated with cooling of the milk tank [6].
Heat pumps are very efficient for heating and cooling
systems, they can significantly reduce the energy cost. They
keep energy cost as low as possible which is the most
important thing for any industry. The performance of the
heat pump can also be described by COP. This method of
cooling uses the refrigeration evaporator pipes or specially
designed flat pillow-shaped plates that are attached to the
bottom outer side of the tank containing milk. The heat of
the milk is transferred through the walls of the tank to the
refrigerant. The refrigerant then absorbs the heat of the milk
inside the tank. The milk cooling process takes place inside
the tank and normally an agitator is used to continuously
mix the milk to prevent it from mixing at the bottom of the
tank. Ice water cooling is another method used for the
cooling of liquids in bulk tanks. The small compressors are
normally used to build up a reserve of ‘coolth’ in the form
of ice over a long period of time. The ice is normally formed
on the copper pipes through which the refrigerant passes and
the ice is surrounded by the water close to freezing point [7].
The water generally surrounds the outside of the tank while
agitator is used to mix the milk inside the tank. The
advantage of this method is that the ice can be made anytime
and not only during the time when content must be cooled.
This method is not as effective as a direct expansion method
because the heat must be transferred several times (from ice,
to water, to the milk). The other disadvantage of this method
is if the ice has melted, it must be made all over resulting in
high electricity usage.
In this research a smart cooling system is proposed
based on the thermoelectric cooling module (TECM). A
similar approach has been proposed in [8]. TECM, also
known as Peltier cooler, because it is based on the Peltier
effect is a semiconductor-based electronic component that
functions by removing the heat from one side to the other
when a low DC power source (12 V) is applied. One side of
the module is cooled while the opposite side is heated [9].
The working principle of the TECM is shown in [10]. The
heat flow out of the module has a significant impact on the
overall system performance. The larger temperature
difference that the module must work against, the smaller
the quantity of the heat removed for the cold side. The
performance of TECM and any other cooling device can be
compared by determining their coefficient of performance
(COP) [11]. The advantage that a TECM has over a
compressor is that they have no moving parts and do not
require the use of chlorofluorocarbons. This makes them

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perfect for application since they are environmentally
friendly [12].
II. PROPOSED DESIGN
Fig. 1 shows the overview and operational analysis of
the proposed system which describes the actions that the
end-user will have to perform in order to operate and
monitor the system.
The end user will at first, must switch the system on and
check the alarm indications - whether all the components of
the system are connected and functional. If the alarm system
indicates certain components of the system are disconnected
or malfunctioning, the end user will have to replace or
connect them to the system and monitor the alarm system
again to verify that they all connected. When the alarm
system indicates positive results, the end user will have to
operate the controller with the aim to check/ monitor the
temperature and the level of the milk. The end user will also
monitor the power being consumed by the system. After the
process of operating the system, the end-user will then have
to deliver the cooled milk inside the tanker to respective
dairy processing plants. The control unit will have the
buttons and screen through which the end-user will operate
to view the status (level and temperature) of the milk inside
the tanker.
The TECM from laird technology/TE technology Inc.,
usually comes with heat sink and fan already assembled,
depending on the application for which they are needed. The
cooling capacity of the thermoelectric cooling system is
dependent on the operating temperature of the content
desired for cooling, quantity of thermoelectric modules
used, the type of thermoelectric module used and the applied
power. The Marlow guide [13], will be used in this case to
select the applicable TECM which will be compatible for
the research. Firstly, the heat load capacity of the milk needs
to be determined to select the applicable TECM which will
be able to provide cooling capabilities. As such, the selected
TECM must be able to handle the temperature difference of
34 °C. The cooling capacity of the milk, in this case, is
determined to select the right TECM for the application.
Equation (1) can be used to estimate the heat load/capacity
of liquids [14].
QC = mC T t = VC T
Where, 𝑚 is cooled substance mass (kg), 𝐶 is cooled
substance specific heat capacity (J/(kgK)), Δ𝑇 is cooling
temperature difference (K), 𝜌 is cooled substance density
(kg/L), 𝑉 is Volume of the cooled substance (dm3) and Δ𝑡 is
cooling time (s). Although our research was based on milk
cooling, water was used as a viable substance to cool.
Connect/replace
the components
unsuccessfully View the
connected/damag temperature
ed and level of
milk inside the
tank
Switch the Check Operate
system ON alarm control unit
indications
View power
consumption
information
Fig. 1. Operational flow diagram of proposed system.
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The density of the water was 1 kg/L, its heat capacity
was 4.2 KJ/(kg*K). The heat load capacity of 50 L of water
is: 661.1 W. Considering the safety factor of 20%, cooling
capacity of 50 L of water/milk is: 1.2 *661.1 = 793.3 W.
The TECMs chosen, must be able to pump this amount of
energy to cool 50 L of milk to 4 °C within the estimated time
of 3 hours.
Table I, shows the heat load for different levels of water.
It is evident that the heat load doubles whenever the quantity
of the milk doubles. The heat loads calculated using
Equation (1) is only an estimate and something to work on
regarding choosing the right TECM for the research. The
liquid cooled TECM (Laird Technologies LA-115-24-02-
0710) that was used is shown in Fig. 2.
This module has the voltage rating of 24 V, current
rating of 5.8 A and power rating of 139 W. This Single
Assembly, from our heat load capacity calculation of the
water/milk, would be able to cool 8 L of milk/water to a
temperature of 4 °C within the period of 3 hours.
Approximately 7 of these TECM assemblies will be able to
cool 50 L of water/milk. These approximations are only
theoretical, and they do not account for the shape of the
tanker and all other factors which might affect cooling
process of the tanker.
Simulation was done later in SolidWorks® to estimate
the cooling capacity that is needed for 50 L of milk.
Simulation results provided more accurate approximations
because in this case other factors which can influence the
cooling process were considered. The eTape liquid level
sensor from the Milone Technologies Inc was selected for
this research. This sensor output was used by the controller
to calculate/determine the actual capacity of milk inside the
tanker in L. The controller also used eTape results to
determine the temperature sensors that must be activated
and considered to calculate and ensure that accurate
temperature results of the milk are displayed. eTape was
placed in a vertical position inside the tanker and was in
contact with the liquid. The eTape used the radius/diameter
measurement of the tanker which was then used altogether
with the tanker dimensions to determine and display the
liters of the liquid inside the tanker.
(1) TABLE I. HEAT LOADS FOR DIFFERENT QUANTITIES OF WATER
Liters (L) Qc heat load (W)
1.0 15.86
3.0 47.80
5.0 79.33
10 159.67
20.0 317.33
30.0 476.00
40.0 634.67
50.0 793.33
Deliver the
milk
Fig. 2.Utilized liquid cooled TECM.
 A thermocouple was selected as the temperature sensor Start
to be used for the research. Three thermocouples were
placed at different levels inside the tanker and their output
was connected to the controller. The controller was
programmed to only display the average temperature sensed Input solar power
measurements (P)

by the thermocouples in contact with the liquid. One

thermocouple was used to sense the temperature No

surrounding the tanker. Four thermocouples were needed Use battery No

Solar power
sufficient?
Yes
Use so lar energy
directly

for this for the research. The thermocouple sensor had the
Yes

requirement of being able to measure the minimum

Solar power st ill
temperature of -5 °C and maximum of 40 °C, as the available?

temperature ranges of the liquid sensed were within this

range. The controller also used the imbalance of 10% Yes
Battery fully Charge battery
No
charged?

(within the sensors placed inside the tanker) to activate the

mixer to ensure that temperature of the milk was distributed
and accurately displayed. Type K thermocouple sensor from
RS-pro was used. This industrial manufactured sensor has a
temperature range of -50 to +400 °C [54], which was viable
for the research.
The alarm system for the research consisted of light
emitting diodes (LEDs) which indicated the status of the
system components such as photovoltaic (PV) (1st Power
Supply), the battery (2nd power supply) and the state of the
mixing unit. The green LED was used for indicating the
connection of the PV panel to the system, yellow LED was
used for indicating the presence of the battery in the system
and lastly the blue LED and red LEDs were used for
indicating the status of the mixing unit. The blue LED was
activated when the mixing unit was in operation and the red
LED was used to indicate the off state of the mixing unit.
The operator (driver) was able to view the status of the
components and able to make informed decisions thereafter.
The alarm system also indicated whether the control system
was supplied through the PV or the battery and this was
indicated by means of green and yellow LEDs, respectively.
Fig. 3. Implemented control flow diagram.
When the measured liquid level was between the
minimum level and the median level (L2), only the first
thermocouple (T1) measurement was considered. T1 and T2
were considered when the water level was between L2 and
L3 (maximum level).
T3 together with T1 and T2 were considered when the
liquid level was above L3. The average temperature (Tavg)
sensed by the thermocouples, was calculated together with
their temperature deviation (Tdev). When the average
temperature of the liquid was greater than 4 °C, the cooling
units continued to be in activation state until the average
temperature was less than 4 °C. The mixer was activated
when the temperature deviation was greater than 10% and
deactivated when the temperature deviation was less than
10%.
The energy management control flow (shown in Fig. 4)
was implemented on the PLC controller. Table II
summarizes the abbreviations used in Fig. 4.
Start

This controller was used to implement the temperature No

control unit and energy management unit of the system. The END

PLC read the information, gathered through the sensors Yes

Measure liquid No

discussed, and took control steps to meet the specifications

System off? level (L)

of the research, such as maintaining temperature of the L > L 1? No

TECM
activated?
Yes
Deactivate
TECM

liquid between 3-4 °C. In the temperature control unit, the

Yes
TECM Activate
No TECM
PLC used the temperature sensors in contact with the fluid
activated?
Deactivate No Yes
Mixer Yes

and displayed their average sensed results. The PLC No Yes L > L 3? No L2< L < L3? No L1 < L < L2?

required level measurements from eTape to decide which Activate Mixer Yes Yes TECM
Mixer activated? Measure T1, Measure T1 No deactivated?
Yes Measure T1
T 2, T 3 & T2
temperature sensor to consider. In the energy management No
Mixer
No
Tdev > 10%? Yes
activated Yes Calculate
unit, the PLC decided on the energy source that needed to Tavg

be used depending on weather conditions. The PV was the Tavg > 4°C?

primary source while the battery was the secondary source. Fig. 4. Energy management control flow diagram.
The battery was utilized when there was insufficient energy
from the PV due to weather conditions. The PV charged the TABLE II. SUMMARY OF ABBREVIATIONS USED IN FIG.4
battery and supplied the system when there was sufficient
energy during sunny days. The PLC also managed the alarm Abbreviation Description
system of the research by sending the switching instructions L Measured liquid level
to the LEDs depending on the input information it received L1 Minimum liquid level of the tanker
from the system’s components. L2 Medium liquid level of the tanker
L3 Upper Liquid level of the tanker
Fig. 3 shows the suggested control flow diagram that T1 Temperature sensor placed at minimum liquid level
was implemented. In this flow diagram, the system first T2 Temperature sensor placed at medium liquid level
determines the amount of milk that is inside the tanker. The sensor
system uses the minimum level (L1) as the level at which the T3 Temperature sensor placed at the upper liquid level
cooling occurs, as to avoid wasting energy during the time TECM Thermoelectric cooling unit
when the tanker was empty. TECM started to be activated Mixer Agitator
when the water level was above the minimum level. Tavg & Tdev Average temperature and temperature deviation

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 In the flow diagram, it is seen that the energy of the PV
was first determined/measured and decided if it’s enough to
power the system. This required both the voltage sensor and
current sensor be implemented to determine and monitor the
power from the PV. During sunny days, the energy of the
PV is likely to be enough to power the system and
simultaneously charge the battery. During the night or bad
weather conditions, the energy from PV is likely insufficient
to power the system directly, hence a battery was needed as
a backup source. The power measurement from the PV
allowed the controller to determine which power source to
use between the PV and the battery. The voltage sensor
(voltage divider) was also used to sense the voltage capacity
of the battery to determine or monitor its energy capability.
This sensor was connected to the analog input of the PLC to
allow the implementation of flow diagram shown in Fig. 3.
Since there three sensors were used to implement the energy
management unit, three analog inputs of the PLC were used
for this purpose.
For current sensing measurements, the shunt resistor,
together with the current sense amplifier, was used to take
the current measurements from the PV. The power of the
PV was then determined from the current and voltage
measurement of the PV. This power calculation was then
used to determine if the PV is able to supply sufficient
power or not. Fig. 5-Fig. 7 shows the temperature analysis of
the tanker.
Fig. 5. Temperature analysis with one TECM placed at lowest level in
tanker.
Fig. 6. Temperature analysis with three TECMs placed along sides of the
tanker.
a) 2 TECMs b) 3 TECMs
Fig. 7. Temperature analysis with TECMs placed parallel to bottom of
tanker.
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The TECM was operated outside the tanker with copper
coils placed inside, for direct contact with the milk/water.
The purpose thereof, was to see how the temperature was
distributed within the milk upon the placement of the copper
coil to the relevant place inside the tanker. Only one TECM
was available for the research and the SolidWorks®
simulation was done to investigate the effect of this module
inside the tanker. The minimum temperature of the provided
cooling module was -10 °C. Ethanol was chosen as the
circulating liquid which will flowed through the heat
exchanger of the TECM. In the simulation, the temperature
of the ethanol entering the copper coil was set at -10 °C. Fig.
5 shows the temperature results of our analysis. It was
considered that the coils were placed at the minimum level
of the tanker to allow cooling when the liquid level is at that
point.
The surrounding temperature of the tanker was set at 25
°C since this was the temperature regarded as room
temperature and the water was used as a liquid to be cooled
with an initial temperature of 38 °C. In Fig. 5, the copper coil
only managed to cool the liquid near it and as such, the
agitator was needed to mix the liquid and ensure that the
temperature of the liquid was well distributed. This setup of
the tanker required that the agitator be placed in the parallel
position to the tanker to allow the movement of the cooled
liquid to mix with the hot liquid as seen in Fig. 5(a).
The thermocouples for this scenario, had to be placed at
different levels of the tanker. One thermocouple was placed
at the bottom level of tanker, the second thermocouple was
placed in the middle of the tanker and the third
thermocouple in the top level of the tanker. The fourth
thermocouple sensor was placed outside of the tanker to
read the outside temperature. This setup in Fig. 5, was
implemented as there was only one available TECM. The
tests on the tanker were conducted to evaluate the cooling
capability of this cooling module.
Fig. 6 shows the thermal analysis of the tanker when there
is multiple liquid cooled thermoelectric cooling modules.
The position placement of three TECMs was investigated in
this regard, to determine how the liquid was cooled in these
scenarios. In Fig. 6, the tanker was connected to three
TECMs whose coils are placed perpendicular to each other.
This set up of coil placements is not proper since the
temperature at the top is not cooled. The liquid at the bottom
of the tank will also freeze due to high concentration of
cooling happening at the bottom. Hence the choice of
placing the cooling coils in this manner is not proper. In Fig.
7, the three TECM copper coils are placed in a parallel in
accordance with the levels of the tank. The cooling in this
case happens much better that in Fig. 6. The temperature of
the water in Fig. 7 is mostly seen to be around 3-7 °C. This
proves the setup in Fig. 7 is better than the setup in Fig. 6.
III. RESULTS
The subsystems discussed above were all integrated to
realize the intelligent solar powered TECM road milk tanker
shown in Fig. 8. This figure shows the setup of the research
where 8.91 L of water was inside the tanker as indicate on
the LCD screen. The LCD screen also displays power
consumption. The PLC recorded the temperature to be 7℃
inside the tanker and the surrounding temperature was 18
℃.

Fig. 8. Integrated intelligent solar powered TECM road milk tanker.
Two tests were performed in order to evaluate the
system performance and determine the efficiency of the
system. The results were used in order to draw a conclusion
on how, on the big scale, the system performed. The ability
of TECM as a cooling unit was evaluated and tested as to
predict how many TECMs were needed to ensure that the
system becomes more efficient in terms of cooling. The
ability of the tank to preserve and maintain the cooled
temperature will be discussed. The critical tests that were
conducted were the cooling ability and the temperature
control.
A. Test 1: Cooling ability
This test determined the ability of the tanker to cool the
milk. Water was used as a viable liquid that was cooled and
tested even though the objective of this research was to
design the tanker which will be able to cool the temperature
of the milk from 38℃ to 4 ℃ within a time period of 3
hours to ensure that the quality of the milk is preserved. 7
L and 21 L of water were externally heated up to a
temperature of 38 ℃. 7 L of this hot water was filled inside
the tanker first and the test was performed. 21 L of hot
water was filled secondly, and the cooling test was
conducted. The temperature measurements of the critical
sensors were recorded and noted while the system was
being operative for 3 hours for both cases of 7 L and 21 L.
Fig. 9 shows the cooling test results for both the cases. The
system managed to cool down 21 L of water from a
temperature of 33 ℃ to a temperature of 19℃ within the
period of 3 hours. On the other hand, the system only
managed to cool down the temperature of 7 L of water from
the temperature of 30 ℃ to the final temperature of 13 ℃.
Fig. 9. Liquid cooling test results for 7 L and 21 L, repsectively.
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The cooling test results from Fig. 9 indicate linearity
hence the trend line was drawn. With these results, we were
able to estimate after how long the system will be able to
cool the liquid to the temperature of 4℃. These results
shows us that the cooling unit (TECM) had insufficient
cooling capacity for this tanker. The TECM that was used
in this research has a cooling capacity of 113 W which is
insufficient to ensure that the temperature of the liquid is
cooled and maintained up to the temperature of 4℃ within
the period of 3 hours. The heat load for specific amounts of
water were calculated and estimated in Table I. From this
table, this cooling unit was to cool 7 L content to 4 °C within
3 hours. Because of the surrounding factors which dissipate
heat, like the electric fuel pump, this was not realized. From
Fig. 9, it is safe to conclude that two of these TECMs should
be able to cool down 7 L of water from initial temperature
of 38 ℃ to the final temperature of 4 ℃ within 3 hours.
B. Test 2: Temperature control
The objective of this test was to determine the ability of
the tanker to maintain the temperature of the liquid between
3 and 5 ℃. The ice cubes were filled inside the tanker so
that the temperature of water can initially be below 4 ℃. Ice
cubes were added to the 7 L of water that was tested for
cooling. The water capacity after the ice cubes were filled
changed to an average water capacity of 9 L. The critical
sensor, which in this case is sensor number one, initially
registered a temperature of 2 ℃ as can be seen in Fig. 10.
The system was then off for a period of 40 minutes. The
system turned on when the temperature of 4 °C was
exceeded. This is indicated by the profile of current
measurements plotted in Fig. 10. The temperature of water
continued to rise even when the system cooling unit was
activated. The temperature of 9 L of water continued to rise
until it settled at 7 ℃ after 120 minutes. The temperature of
the liquid continued to be between 6 and 7 °C for the
remaining period of 1 hour. The behavior of current when
this happened is shown in Fig. 10. During the time when the
system was off, the temperature of liquid inside the tanker
changed from 2 ℃ to 4 ℃ within the space of 40 min.
Fig. 10. Results for temperature control test.
 This result proves that the tanker was not efficient
enough to hold and maintain the temperature of the liquid
for an extended time. This is not surprising since the tanker
did not have insulation between the outside part of the
tanker interacting with the environment and the inside of the
tanker which interacts with the liquid. This means that
insulations needs to be applied to this tanker. The tanker can
store 50 L of milk, as such this required a cooling unit with
minimum cooling capacity of approximately 800W
according to Table I. Taking into account environmental
factors, it would be safe to use a cooling unit with cooling
capacity of 1200 W. Using TECM as a cooling unit, 12 will
be required. For an actual tank of 8000 L, the cooling unit
used shall require a cooling capacity of 192 kW. This will
require 1920 TECMs.
IV. CONCLUSION
This research was based on designing and implementing
a small scale intelligent TECM road milk tanker. The
proposal was drafted and a brief background about the
research was presented. The problem stated that an
intelligent solar powered road milk tanker needed to be
developed to lower the cost associated with cooling of the
milk. Research was compiled on available solutions which
can be used in order to implement the research. All the
critical subsystems like liquid measuring, power monitoring
and temperature control of the research were integrated and
found to be working accordingly. Two types of tests were
performed to determine the cooling ability of the tanker. It
was found that the cooling of the tanker was not efficient as
the temperature of 4 ℃ could not be reached by the
minimum capacity of the tanker in a period of 3 hours. It
was decided that the cooling capacity of the TECM is not
sufficient to realize the objectives of cooling the liquid to
temperature below 4 ℃. The temperature control of the
tanker was also not efficient due to the fact that the
temperature of 9 liters of water was not controlled at the
required set point for the period of 1 hour. It was suggested
cooling units with sufficient cooling capacity be used
instead. Comment was made regarding how many of these
TECMs were needed and what can be done to improve the
tanker.
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