WHITE PAPER April 2017 All that glitters… may not be an effective cargo cover in all situations
How the properties of cargo covers affect their performance in real exposure conditions.
Dr. Steve Brabbs, Dr. Srinivas S Cherukupalli, Lawrence M Knorr, Alain Weimerskirch E.I. DuPont de Nemours & Company
Background Properties important for passive thermal covers During most stages of the journey of a pharmaceutical ship- It is likely that cargo will be exposed to ambient temperatures ment, the external environment can, at least in principle, be outside the acceptable range during breaks in the cold-chain, maintained at a temperature which will not be deleterious to so it is important for a cover to separate the goods from the the efficacy of the product, be that in a temperature controlled external environment; i.e. when the temperature of the outer warehouse, a reefer truck or container, the refrigerated hold surface varies, the resulting temperature gradient across the of a ship or in the cargo hold of an aircraft. If temperature cover should not result in a significant heat flow through deviations occur in these areas, they can usually be resolved the cover. This insulation property is most usefully expressed by improvements in infrastructure, procedures, training and in terms of the thermal resistance or ‘R-value’, with units communication of handling requirements down the chain. m²K/W. R-value is the temperature difference across the Much progress has been made in improving best practice for cover which will cause a heat flow of 1 W through 1 m² of temperature controlled pharmaceutical shipments and today, surface, and it can be calculated by dividing the thickness of most would agree that while cold-chain breaks still happen, the cover (in m) by the thermal conductivity (in W/mK) of they occur more often than not during handover from one the material from which it is made. A higher R-value means controlled environment to the next. Examples would be dur- the cover can maintain a higher temperature difference and ing loading or unloading of an aircraft, charging a load into still have a low heat flow. Of course, if there is a temperature a reefer truck at a warehouse dock, or during the last mile difference, heat will always flow to equalize the temperatures, delivery to smaller pharmacies or clinics. The common factor so with any cover the load temperature will eventually reach in these handovers is that the cargo must be moved outdoors the outside temperature. However, if heat flow is low, this for a time, so the external conditions may well be outside the process is slowed, so a higher R-value translates into a longer specified range for the product in question. exposure time before the cargo temperature goes outside the Shippers use a variety of solutions to mitigate the effects of allowed range. uncontrolled external conditions, including powered contain- But how is heat transferred between the external environment ers with autonomous heating and cooling systems, or insulat- and the outer surface of the cover? One mechanism is by direct ing box systems equipped with phase change materials to help contact with the hot or cold air surrounding the cover, but maintain a stable internal temperature. For Controlled Room unless wind speeds and/or temperature differences are very Temperature (CRT) shipments, a common risk management high, this convective heat transfer is relatively weak because air solution is a cargo cover or cargo wrap fitted over the pallet to is a rather poor heat transfer fluid. isolate it from the external environment. In selecting such cov- ers, shippers must understand the specific risks of the intended A second heat transfer process is direct emission or absorption shipping route and how the covers will respond to those risks. of radiation by the outer surface of the cover. Many covers This article describes a study conducted to compare different attempt to minimize this using aluminum foil or a polymer types of covers in controlled but realistic exposure conditions, film coated with a thin layer of aluminum to provide a shiny, to better understand the relationship between cover proper- metallic surface having a low emissivity. Instruments used ties and real-world cover performance. to measure emissivity operate at wavelengths of 8000 nm or greater, so emissivity values are useful in assessing radi- clear day, direct solar radiation can easily reach a radiant flux ant absorption or emission in this far infra-red region of the of around 1200 W/m2. However, the surface temperature spectrum. The peak wavelength of thermal emission from an of the sun is of the order of 5500°C, which means that the object, λmax, may be estimated using Wien’s law: peak wavelength for its emitted radiation is about 500 nm,
λmax = b/T in the visible part of the spectrum. This is very much what is observed in the solar spectrum measured at ground level. As where T is the temperature in kelvin and b = 2.898 x 10-3 mK. For can be seen in Chart 1, the peak in radiant energy in sunlight is a CRT cargo with a temperature around 20°C the peak emis- far from the infra-red wavelengths used in emissiviometers, so sion wavelength should be about 11000 nm so a low emis- a low measured emissivity does not predict that a material will sivity cover will reduce the rate of cooling by radiation if the load is placed in a cold environment. In a hot environment, have low absorption of solar energy. For this, high reflectance incoming thermal radiation comes from the ground and in the visible and near infra-red is a more useful parameter, from nearby objects which could have temperatures as high because the more of this incident energy is reflected back into as perhaps 80°C which corresponds to a peak wavelength the surroundings, the less can be absorbed. of about 8200 nm. Again, if the cover has a low emissivity, Experimental absorption of these wavelengths coming from the surround- Reflectance was measured for electromagnetic radiation of wave- ings will be poor and the rate of heating will be reduced. lengths in the range of 400 nm – 1050 nm, covering visible and As most cold-chain breaks occur outdoors, a source of radiant near-IR wavelengths, using a Hunter Lab Ultra Scan ProD65 energy which cannot be ignored is, of course, the sun. On a instrument. ASTM E1331 standard was followed for these tests.
Chart 1- Solar Irradiance at Earth's Surface Source - US National Renewable Energy Laboratory 1,75
ASTM G173-03 Reference 1,50 Spectrum
1,25
1,00
0,75
0,50
0,25 VISIBLE INFRA-RED
0,00 250 500 750 1000 1250 1500 1750 2000 2250 2500 Wavelength nm
2 Thermal conductivity was measured according to ASTM so the variety of covers in use today reflects different com- C518 using a 30 cm x 30 cm sample held between the plates promises between all these aspects. The cargo covers selected of a Netzsch HFM 436/3 Lambda instrument with a tem- for this study were representative of different structures used perature gradient of 20⁰C and the top plate maintained at to protect CRT pharmaceutical shipments. They included 25⁰C. Heat flow from the hotter surface to the cooler surface a metallised film laminate, two examples of covers based on through the sample was measured until equilibrium was metallised bubble wrap, a multi-layer metallised thermal blan- attained. Thermal resistance (R-value) was then calculated ket and white, single side metallised Tyvek® non-woven covers as the sample thickness divided by its thermal conductivity. with and without an inner insulating layer. They were selected For thin samples (<3 mm thickness), a transient plane source to cover a range of R-values, reflectivities and emissivities and (TPS) in-plane thermal conductivity value was measured their measured properties and descriptions are summarized in using a Hot Disk TPS 2500S instrument with a 5465 sensor, Table 1. and the resulting R-value was calculated in the same way. Emissivity was analyzed using a Devices & Services Co., Model AE1 instrument and calibration was achieved by mea- suring emissivity of standard black and white body samples. ASTM C 1371 was used as the reference standard for these tests. Selection of cover types tested While the primary purpose of a passive thermal cover is ther- mal protection, there are other characteristics which must be considered by users. Weight, bulkiness, and flexibility will impact on ease of use, storage, and shipping. It is desirable for a cover to provide adequate protection from rain, snow, dust, and other contamination, and recycling and sustainability may also be considerations. Cost is, of course, an important factor
Table 1 – Measured properties of covers used in the trial
Reflectivity Thermal conductivity R-value Emissivity Sample 400 - 1050 nm 2 Description W/mK m K/W %
ML1 82.0 3.2* 0.0001 0.03 Metallised laminate
White Tyvek® 0.14/0.45 W20 93.4 1.2* 0.00014 non-woven, in/out metallic layer inside.
Metallised MBW1 84.6 0.0419 0.155 0.06 bubble-wrap
Metallised MBW2 79.9 0.0400 0.190 0.16 bubble-wrap
White Tyvek® non-woven, W50 91.3 0.0326 0.267 0.45 metallic layer + insulation fleece.
MTB1 75.0 0.0326 0.447 0.37 Metallised thermal blanket
*conductivity measured by TPS method
3 Chart 2 below compares the reflectivity spectrum of the white at the location of each logger, and two additional temperatures Tyvek® W20 cover compared to that of the MBW2 cover, from separate locations under the cover, with the possibility to measured over the wavelength range from 250 to 2500 nm. download data via the USB extension cable without disturbing The reflectance spectrum of MBW2 is typical of all the metal- the load or removing the covers being tested. The sensors were lised covers tested. Comparison with the solar spectrum in distributed through each pallet in identical locations shown Chart 2- Spectral Reflectivity of Cargo Covers 100
95
90
85
80
75
Reflectvity (%) 70
65
60 Tyvek® W20 MBW2 55
50 250 500 750 1000 1250 1500 1750 2000 2250 2500 Wavelength nm
Chart 2 shows that the white Tyvek® cover has higher reflectiv- in Diagram 1 below, so that temperatures were recorded from ity where the solar spectrum is most intense in the visible and fifteen separate positions within the load. During outdoor near infra-red part of the spectrum, while the silver-coloured exposure, the pallets were placed with the same face always ori- MBW2 has higher reflectivity at longer infra-red wavelengths. ented southwards as shown. Inside the boxes at ten positions Simulated CRT loads (extreme corners, the middle of the top face, and the center of the south face), a remote temperature sensor was placed in a Identical pallets were constructed to simulate a low thermal 10 ml vial of isopropanol to approximate measurement of the mass pharmaceutical load of approximately 100 kg. Eighteen product temperature. This was chosen to provide good ther- single walled, 15” cube cardboard boxes were stacked on mal contact with the temperature probe, uniform temperature standard wooden pallets in three layers of six boxes per layer. inside the vial through mixing and because isopropanol would Eleven 500 ml bottles of drinking water were placed in each remain liquid over the whole range of temperatures foreseen. box to give a total of 198 bottles, or 99 kg of water distributed Isopropanol is also relatively safe to handle and has a lower throughout the load. Onset Hobo U12-013 data loggers were specific heat capacity (2.68 J/g°C) than water-based pharma- used to record temperature and relative humidity during each ceutical formulations so is a conservative choice in this regard. trial run, and each logger was equipped with two TMC6-HD remote temperature probes and a USB interface extension cable leading to the outside of the pallet. This allowed simulta- neous recording of one temperature and air relative humidity
4 Diagram 1 - Positions of data loggers and orientation to compass directions. Corner locations 1, 2, 3, 4, 8, 9, 10, 11, top face location 6, and south face location 5 indicate temperature probes in 10 ml vials of isopropanol. Locations 7 (top center, under cover), 12 (south facing, high), 13 (south facing low), 14 (core), and 15 (north facing middle) are air temperature measurements. The following photographs illustrate the construction of the test pallets. Top Corners
Top Face
South Face Air High Bottom Corners
South Face Air Low
After building all the pallets as described, each was protected were equilibrated in a controlled, air-conditioned warehouse with a different type of cover according to the manufacturers’ having a temperature of 20-22°C. The test pallets were con- instructions. Note that in both tests discussed, no base was used structed in this warehouse and were maintained at this tem- between the boxes and pallet. perature before and between tests for a sufficient time to ensure Exposure tests all the loggers on all the pallets were at a uniform temperature, Internationally recognised standard protocols could not be fol- within a range of ±1°C. lowed as the purpose of our experiments was to explore factors For high temperature experiments without solar exposure, a not covered in such standards as exist in this area. All test pallets heated container was constructed using a Carrier Tansicold Elite 5 Chart 3 - Temperature uniformity of 40°C container during 8 hour test
Line Model 69NT40-531-01 insulated refrigerated container loading area outside the temperature controlled warehouse was connected to a loading dock of the warehouse. Data loggers used. This was located in Miami, Florida, USA (25.8°N) where were attached to the floor and walls to monitor temperature high temperatures and strong sunshine are to be expected in the stability and uniformity. The distribution of hot air through summer months, and the trials were carried out on predomi- the container was initially found to be uneven and the capacity nantly clear days in August 2016. This solar exposure area was of the heating units was insufficient to achieve the 40°C target. south-facing and not overlooked by buildings or other objects Plywood was placed on the bottom of the container to cover which could shade any part of the test area during the test. After the floor air channels for the majority of their length in order re-conditioning at 20°C, the test pallets were moved to the out- to direct air towards the door end, and mobile, closed loop door test area shortly before noon to simulate a ramp handling controlled electrical heaters were installed to boost heating event at a tropical airport during the part of the day when solar capacity. In this way, more uniform spacial temperature distri- exposure is strongest. The pallets were placed well apart (at least bution at the target temperature was achieved. twice the pallet height) to ensure that one pallet could not cast a To conduct the trial, test pallets conditioned at 20°C in the air shadow on its neighbour during the test. After approximately 4 conditioned warehouse were moved into the heated container hours exposure, the pallets were returned to the air conditioned in an operation lasting about 10 minutes, the container doors warehouse and stored overnight. The data from the loggers was were closed and the trial was left to run for eight hours. There then downloaded using the previously installed USB exension was a dip in temperature especially near the floor when the doors cables. During the solar exposure a portable weather station were opened for loading, but this was short relative to the dura- (Onset Hobo U30 NRC with upward and downward facing tion of the test. At the end of the 40°C exposure time the pallets Kipp & Zonen SMP3-A pyranometers) was set up adjacent were returned to the air conditioned warehouse overnight and to the test area to record direct and indirect solar intensity, then the logger data was downloaded via the extension cables, wind speed and air temperature during the test. Data from the allowing the covers to remain in place and minimizing handling. weather station are summarised in Chart 4 below. For high temperature exposure with solar radiation, a concrete
6 Chart 4 - Weather station data collected during solar exposure trial
As can be seen from the chart, the sky was clear during most of the analysis presented here, all data from positions within the the trial, with only five brief dips in solar intensity when clouds pallets which showed anomalous behaviour. While the results passed in front of the sun. The peak solar intensity reached should be regarded with some caution, the overall pattern is about 1100 W/m2. The air temperture ranged between 34°C consistent and the data presented here have been selected to and 37°C and the average wind speed was below 1 m/s, with illustrate this. gusts just exceeding 4 m/s. The following charts show the results from the data loggers Results recorded during exposure of the pallets to temperatures above In the heated container trial, in many cases the top corner log- the 15-25°C CRT range, with and without solar exposure, gers recorded the highest rate of temperature incease, followed from data loggers recording air and simulated product tem- by the top centre, then the sides, then the bottom corners and perature in the top of the box in the middle of the top face, and lastly the centre of the pallet. This is what would be expected, simulated product temperature in the outer face of the box given that heat will flow most quickly to loggers which are in the middle of the south-facing side of the pallet. The data close to outside exposed surfaces and that hot air will tend to presented here were obtained using the equipment and in the rise under the pallet cover. However, some pallets displayed specific experimental conditions described above, and should anomalies in temperature distribution which we believe to not be taken as universally applicable. It is advisable for users of have been caused by air currents enterning the bottom of cargo covers to conduct their own investigations under condi- the pallet from gaps in the floor, or local air currents caused tions relevant to their particular circumstances to confirm any by the additional electric heaters used to boost the heating of the present results which may be of interest. capacity of the container. The equipment design had practical advantages in allowing tests to be carried out quickly and eco- nomically, but its limitations in local temperature uniformity should be recognised. For this reason, we have excluded from
7 B Top Air B Top Air B Top Air B Top Air B Top Air B Top Air L Top Air L Top Air L Top Air TB Top Air TB Top Air TB Top Air Top Air Top Air Temperature C Temperature C Top Air
Temperature C Top Air Top Air Top Air posure Time min posure Time min Chart - Thermal cham er no sun - air temperature top Chart - Thermal cham er no sun - air temperature top