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Design and Analysis of an Efficient Vaccine Cold Chain Box

Conference Paper · November 2016

DOI: 10.1115/IMECE2016-65858

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 Proceedings of the ASME 2016 International Mechanical Engineering Congress and Exposition
IMECE2016
November 11-17, 2016, Phoenix, Arizona, USA

IMECE2016-65858

Design and analysis of an efficient vaccine cold chain box

Shitanshu Devrani1 ; Sudhanshu Pandey2 ; Shubham Chaturvedi2; Krishnakumar Sankar1;

Dr. Shantanu Patil1; Dr. K.Sridhar1

1 Department of Translational Medicine & Research, SRM Medical college, SRM

University Chennai, Tamil Nadu, India; 2 SRM Engineering College, SRM University,
Chennai, Tamil Nadu, India Corresponding Author : shitanshu_261@hotmail.com

ABSTRACT which is not maintained effectively throughout the

Human health is one of the most important concerns for the
governments around the world. Global organizations such as
WHO (World Health Organization) and PATH (Program for
Appropriate Technology in Health) have considerable interest
in organizing vaccination programs and its cold chain delivery.
The problem predominantly persists in Lower-middle income
countries like India where due to inadequate infrastructure and
lack of consistent Power supply, significant losses occur in the
cold chain. Improvements are required to prevent the loss of
costly and precious vaccines during the cold chain. India lacks
a reliable power supply and the resulting power cuts interrupt
the cold chain, leading to a loss of vaccine potency since they
are not within the temperature range of 2-8 ºC. This paper
studies the current VCB (vaccine carrier box) and cold chain
design through the aid of Computer modelling and simulations.
Also a novel experimental setup to examine insulation R-value
has been devised and studied. Based on this a new design
approach is utilized to model a thermoelectric system and early
designing is done through the aid of 3-D printing.
Keywords: Vaccine Box, Cold chain, R- value, Heat transfer,
thermoelectric system
INTRODUCTION
In the near future, the world population is expected to reach
almost 10 billion. This is bound to increase the world food and
health care demand. A significant per cent of food and
healthcare medicines like vaccines go to waste due to improper
storage and transportation. A primary reason for this is that
these products require very specific temperature for storage
cold chain. Focusing on vaccines specifically, there are
currently more than 271 vaccines for different diseases
and more are in the development stage. Each varies in
dosage per vial for different manufacturers, hence has
a different geometry of vial in which the vaccine is
stored and sold in the market. This variation in
geometry severely limits the way the vaccine storage
space is utilized inside a vaccine carrier box. A typical
carrier box used lacks an effective holding system for
vials within it. This affects the vaccine carrier’s
performance in terms of storage capacity, storage
duration and ergonomics of the system. This is
especially true in countries like India where hot
climate in the summers can severely affect the potency
of the vaccines.
WHO(World Health Organization) estimates that
reliance on cold chain system may increase vaccine
cost by 20% in the future and possess significant
barrier to access to patient in many developing
countries. In 2011, UNICEF (United Nations
International Children's Emergency Fund) spent 5
times more on vaccines than it did ten years ago. Thus,
a more effective way is required to maintain vaccine
viability. The vaccine trays proposed in this work for
storage can be implemented on the current system.
New designs of vaccine boxes can be developed
around these trays(Lala and Lala 2003; Lloyd et al.
2015; Organization 2013, n.d.).

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 Conway and Brite used Computer aided design and Finite Polyurethane foam (35 to 60 mm thickness) lined by a
Element Analysis to design a VCB. (Brites, Costa, and Costa polystyrene coating is provided on the inside. The
2016; Conway et al. 2012) designed a simple box to increase specimen box used for our analysis is a 1.6 litre
the lifetime capacity of the vaccines. They integrated vaccine space capacity carrier with specifications
systematic slots around the main vaccine space to store an outer given in Table 1. (Apex international, Noida, Uttar
layer of Ice coolant packs and inside a layer of PCM (Phase Pradesh, India)The coolant packs are pre-refrigerated
Change Material) pads available commercially. Bramness et al and usually contain water. These coolants act as
focused on the ergonomics of the whole system, with an passive cooling components. This particular box has
emphasis on shipping and transportation. (Bramness 2010). been designed and analysed further through
They added the features of stackability of sub- parts of the experiments. In silico model of the carrier box was
Vaccine case. Some basic limits to the design are its lack of created using CATIA (Version 5, Dassault Systemes,
storage capacity for an optimized weight. Other efforts by Paris, France)
various innovators have yielded new designs such as the one by
Elena Figus wherein the coolant pack integrated with cotton
made hand bag. This design though very light and easy to
manufacture, fails in maintaining optimum temperature for
longer periods. There have been number of efforts to design
portable Refrigeration system. The proposed design by
(Challenges et al. 2006; Elsarrag et al. 2016; Klein and Reindl
2005) describe solar power vapor-compression cycles and
vapor absorption cycles respectively, to power a refrigeration
system. Besides this, (Elsarrag et al. 2016) proposed a solar
powered desiccant cooling method. (Chatterjee and Pandey
2003)looks into a possible design of specially designed
thermoelectric chests but validation and practical optimization
in to box featured in the work. Design of solar powered thin
film thermoelectric generators have been discussed by
Chatterjee (Chatterjee and Pandey 2003). Various PCM Fig.2a Current design of the vaccine box
materials for cold insulation have been tested throughout The aim of this exercise was to aid the understanding
literature. (Wu, Fang, and Liu 2010) developed a mathematical of the conjugate heat transfer of a vaccine box
model to study cool energy thermal storage system with system(Klein and Reindl 2005; Snorrason and Dalv
spherical encapsulated with n-tetradecane to predict its thermal 2014; Tyagi and Buddhi 2007; Wu, Fang, and Liu
behavior. 2010). The system is treated as a passively cooled
system and based on the heat transfer equation.
NOMENCLATURE Appropriate boundary conditions were also applied.
T=Local Temperature,
t= Time, 𝜕𝑇 𝜐. ∇𝑇 𝑘
+ = +𝐺 (1)
𝜐=Air velocity vector, 𝜕𝑡 𝜌𝐶𝑝 𝜌𝐶𝑝
k=Thermal Conductivity of Polyurethane, Polystyrene, air and
HDPE depending on area of application within the system. 𝐺 = 𝑚𝐶𝑝 ∆𝑇 + 𝑚𝜆 (2)
CP= Specific Heat capacities Polyurethane, Polystyrene, air and Here the first term is a partial differential of surface
HDPE depending on area of application within the system. Temperature with respect to time. Second term is the
𝜌=Density Polyurethane, Polystyrene, air and HDPE depending convective term. On the right hand side the first term
on area of application within the system. denotes the conductive term followed by a Rate of
G=Passive load of the existing coolants within the system taken generation term(Akdemir 2014; Health Canada 2013;
as Heat of generation. Kar 2014; Karp et al. 2015; Klein and Reindl 2005)
𝜆=latent heat of fusion of the PCM used.
th=Average wall thickness of package (cm)
np= Number of plain surfaces
nf= Number of reflecting surfaces
2
R-value units are 𝑚 ℃⁄𝑊
T=Temperature
2. Current Design and applications
The conventional designs used are mostly thick insulated boxes
with coolant packs inside. The main body is generally a HDPE
(High Density Polyethylene) coated frame. Inside a

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 Table.1 Specifications of Conventional Vaccine box
Vaccine Storage Capacity 1.6 Liter
Weight Fully loaded 4.5 Kg
Empty Weight 1.99 Kg
External Dimensions 25x25x30 cm
Internal Dimensions 16.7x16.7x16.7
cm
Vaccine Storage Dimensions 9.8x9.8x9.8 cm
Number of ice packs 4 x 0.4 Liter
Average wall thickness 8.75 cm
Polyurethane foam thickness 45 mm
Fig.3 The image shows Fine hexagonal mesh of the
vaccine box. The problem is shown to be studied from
2 viewpoints. First the heat penetration from the
atmosphere to the surface walls of the box (shown in
a). The other mesh (b) covers the area occupied by the
air coolant packs and vaccine storage space.

Fig.2b Current vaccine box design using CATIA V-5

Boundary conditions and settings applied to the solver:

T=43 ºC outside temperature,
T= 6 ºC inside vaccine space temperature,
T= 0  C coolant body temperature,
Convective heat transfer coefficient, h=11W/m2K at T=43  C
& h=1W/m2K at T=6  C,
𝜆=323 KJ/ (kg K) for water
Other important details have been mentioned in appendix Fig.4a Conjugate transient heat transfer analysis of
outer casing insulating body for 22 hours.
Ansys Fluent (Ansys Inc., Canonsburg, PA, USA) was used to
solve the problem. The finite element model was prepared by
using fine hexagonal meshes with minimum nodal size 0f 0.001
m (fig 2). The solvers used were Energy (1) and Phase change
equation (2) was also turned on. Gravity was also turned on.
The solution was run for 1000 iterations per each time-step
until convergence. For unsteady state, 10000 time-steps each of
8 second intervals were chosen and solved.

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Fig.4b Conjugate transient heat transfer analysis of inner casing
insulating body for 22 hours.
3. Experimental Work
In order to evaluate the Vaccine box performance, we devised a
setup to monitor temperatures at various locations inside a
closed box. Apart from this, the R- value test was performed.
The R-value test is used to find out the resistance value of any
packaging or insulation equipment. It is a quantitative measure
of the complete resistance to heat flow value for the system in
consideration. Principle of the test is that 454 grams (1 lb.) of
water at 32℃ must absorb 144 Btu (363 Kcal/151.9 KJ) of heat
to melt.(Burgess 1999)
The test setup consists of a regular vaccine box with 6
thermocouple (LM-35) probes inside. Within the vaccine
storage space, a non-metallic box with water level sensor
probes was placed. A 7th LM-35 is inserted within this box. All
the readings from 8 sensors (7 temperature and 1 water level)
are sent to a microprocessor chip. The microcontroller used
here is Atmega 2560 in a Arduino Mega 2560 coded to sense
the temperature and water level readings with respect to time.
Display and storage was done on a 16X2 LCD screen. The data
from the setup is stored in a 16 GB memory stick in the form of
a excel sheet.
Fig.5a Experimental setup to calculate R-value (Side view)
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Fig.5b Circuit diagram and schematic representation
of the Arduino system
Ice cubes were added to the non-metallic box which
was placed inside the vaccine carrier box. Around the
interior lining of the box, 2 aluminum foil sheets were
placed separately. The box was closed and allowed to
rest at room temperature. The timer in the system
noted temperature readings within the box from the
placed sensors at 30 second intervals. Besides this the
water level was continuously monitored with water
level indicators. The amount of ice taken was100 g,
this amounts to about 150ml of water. Within the
geometry of the ice box this amounted to about 6 cm
height from the base. Two water level indicators , one
at 3 cm and another at 6 cm were preplaced at the
inside lining of the inner wall of the non-metallic
container. The water level at 6 cm marked the endpoint
of melting.
System
(Box Area)(Temperature Difference)
R−value = (3)
(melt rate)(Latent Heat)
Melt rate
Amount of Ice melting(kg)
= (4)
Time Taken for complete Melting
Box area=Inside surface area of Vaccine box=1.4 m2,
Temperature Difference= Outside Temperature (Room
Temperature) - Inside Temperature(0°C) = 24°C -
0°C=24°C
Latent heat of water= 323kJ/ (kg k)
R- Value obtained for different packages is fitted to an
empirical formula which takes into account the
contribution of conduction, convection and radiation.
R − value =
0.27 th + 0.26np + 0.56nf (±20%) (5)
This helps analyze the contributions of conduction,
convection and radiation into total penetration of heat.

Ice Required =
(Box Total surface Area)(Temperature difference)(Exposure time)
(6)
(R − value)(lantent Heat)
Ice requirement calculations can done once the R value is
decided for the package using equation (6).(Burgess 1999)
Result & Analysis
Fig.5 schematic setup to calculate R-value
Fig.6 Temperature (T°C) vs. time (hrs.) profiles at various
points (T1 to T7)
Temperature (ºC) vs. Time (hr.) plot at various points inside the
Box from experiment is shown in Fig.6at ambient temperature
of 26ºC. Each thermocouple attached has been named
accordingly in the schematic diagram (fig. 5) of the setup and
the corresponding graph has been at each point has been
highlighted in fig 6. The essential conclusion we draw from this
is that within a period of 35 hours the temperatures for all the
sensors placed within the box surpasses the temperatures for
safe keeping of vaccines (2-8 ºC). The broad scatter plots
obtained in fig 7 indicate the fluctuations of temperature with
time. Most notably for the base sensor (T5) reading, large
temperature fluctuations over time are consistently observed.
This fluctuation points towards temperature gradients
developed within the box leading to thermal shocks which
limits the duration of vaccine safekeeping time (35 hr. for
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26ºC). Duration goes significantly down for higher
temperatures as confirmed by our local doctors. This
significant and rapid heat transfer from the base has
also been confirmed by simulation developed in the
previous sections. The reason for this is fairly
intuitional as the base is the continuous source of
conduction through contact with ground. These results
in convective air currents within the box leading to
thermal gradients generated within the system.
Based on the results obtained from the experiments,
Using (4),
0.1 kg Kg⁄
Melt rate = = 0.00768 hr
13.02 hr
Using (3),
(0.14)(24)
System R − value = =
(0.00768(333.55)
2 2
1.3119 m . hr℃⁄KJ = 4.724 m . ℃⁄W
We know that average wall thickness of the box is
about 9 cm, 4 plane surfaces (walls) surround the
vaccine spaces. Besides this 2 aluminum foil sheets
are separately placed within the non-metallic box.
These foils act as the reflecting surfaces in this system.
Using equation (5),
4.724 = 0.27(9) + 0.26(4) + 0.56(2)
From the result obtained, the individual contribution to
heat transfer is 51.43% conduction, 27.51%
Convection and 23.7 % radiation. These numbers
suggest the contribution of each mode of heat transfer
within the time frame of cold insulation of the box for
vaccine storage.
The minimum ice requirement of a system operating at
43ºC outside temperature for a period of 72 hours can
be calculated by using (6) as,
(0.14)(43)(72)
Ice Required = = 0.284 ≈ 0.3 Kg
(4.724)(323)
= 300 g
4. Results and Discussions
In the previous sections, it has been highlighted that
the current box has certain shortcomings. Some of
these are Constant thermal exposure of entire batch of
vaccine every time the lid is opened to take out a
single vaccine vial. This causes frequent thermal shock
to all the vaccines inside. Undefined storage space
contributes to a smaller number of vaccine vials that
can be carried in a typical 1.6L capacity box.
Experiments (fig.5a &5b) and literature survey show
 that there is development of temperature gradient within the
box (especially at the base). This is particularly evident in the
base of the box where continuous fluctuations in temperatures
are followed by a sharp rise. This implies significant heat
transfer from the bottom.
Also Coolant packs are not firmly fixed and undergo frequent
collision within the carrier walls, contributing to damage of the
vials and frequent leakage of the coolant. This kind of contact
can cause freezing of vials below the required temperature
leading to them loosing potency. One of the main problems is
inadequate vaccine safe keeping time for long immunization
programs (1 -1.5 days for ambient temperature 23-30ºC and
less than 1 day for summer temperatures ≥40ºC). Separate
thermal conditioning of the vaccine and coolant packs is needed
before an immunization program. Considering all these
limitations of the current vaccine carrier, we propose a new
design. Such a system should not only keep the potency of
vaccines for longer durations but should also be more
ergonomic.
All available designs are inefficient in utilizing the storage
space inside the box. This is critical since utilizing this space
will not only ensure systematic and safe storage of vaccines but
also improve the accountability for maintaining an inventory. A
tray stacking system is at the core of the new design. These
trays are made up of a suitable plastic with moderate thermal
conductivity (0.5-1 W/mk) and structural load capacity. A
special PCM is encapsulated within these trays. An early design
of such a tray has been 3-d printed. Thermal energy storage
(TES) is a technology with a high potential for different thermal
applications. It is well known that TES could be the most
appropriate way and method to correct the gap between the
demand and supply of energy and therefore it has become a
very attractive technology. The energy storage density could be
increased using PCM, having a phase change (latent heat)
within the temperature range of the storage.
This design limits the thermal exposure when the lid is opened
to the tray in use. This protects the trays kept underneath.
Sufficient protection is provided from the base by such a
system, this is critical since our results on the current design
show that maximum heat transfer for a fully closed box is from
the base.
Thermoelectric coolers (TECs), also known as Peltier coolers,
are solid-state heat pumps that utilize the Peltier effect to
transfer heat. Passing a current through a TEC transfers heat
from one side to the other, typically producing a heat
differential of around 40°C or as much as 70°C in high-end
devices that can be used to transfer heat from one place to
another.
The complete design incorporates a PCM encapsulated tray
stack assisted by a thermoelectric cooling system. In the
conventional design 1.6 kg of water is utilized for cooling
within the coolant packs. The designed trays are meant to hold
about 250 g of PCM each within them. (3 tray stacks are
roughly 800g total). This helps us to reduce the mass of water
within the coolant packs as now we hold about 125 g of water
per coolant pack. Cumulatively this would amount to about 500
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g of water. Thus the TES mass employed is about 1.3
Kg. On the other sides of the coolant packs, 2 Peltier
plates are employed, one at the side and 1 at the
bottom. These plates are run by a 60 W chargeable
battery system. This was calculated after analysing and
quantifying the thermal load involved in this cooling
space. The cooling load calculated was 18 W. The
system was optimized by the help of a power
distributer attached to the battery, the distribution of
power was controlled by a microcontroller which gets
temperature and humidity readings reported by the
probe within the box. Such a design activates the
Peltier plates as a response to a rise in temperature
beyond a particular threshold (5- 6 ºC). Thus, the aim
is to create a ‘smart’ thermal response cooling system.
The outside insulation is cylindrical in shape as it has
the lowest surface area to volume ratio S/V ratio
(besides a sphere).Lower the S/V ratio, lower will be
the rate of heat transfer to the surrounding.
VI. Conclusions
The study here accesses the performance of the current
cold chain box used for immunization programmes.
Findings point towards a need for an improved and
optimized design which not only keeps the potency of
vaccines for longer durations but also makes the cold
chain more ergonomic. The design proposed here
utilizes advanced PCMs as thermal energy storage
systems to eliminate the limitations of the current
design.
The R-value test for the current vaccine box quantifies
the individual contribution to heat transfer as 51.43%
conduction, 27.51% Convection and 23.7 % radiation.
The experiment and CFD (computational fluid
dynamics) analysis verify that the main mode of heat
transfer is from base. The new design is proposed is
cylindrical in shape to minimize the S/V ratio,
allowing a low heat transfer rate. PCM filled tray
system is proposed which through conjugate heat
transfer modelling show that the design can reduce the
heat transfer from the bottom and also reduce the
internal temperature gradients. The new design
proposes a ‘smart’ thermoelectric cooling system
based on thermal response to provide a Semi-active
system of cooling.
ACKNOWLEDGMENTS
The authors of this paper would want to extend their
gratitude to Department of Translational Research and
Medicine for providing major funding for this
research. We would like to thank Dr K.Sridhar ( PRO
VC SRM medical college), Dr KR John (Professor,
Community Medicine department, Dr MP
Rajesh(HOD Chemical Engineering),Dr S Prabhu
(HOD Mechanical Engineering) for their continuous
support and guidance. Besides this we extend our
gratitude to SRM University as a whole.
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