Keeping temperature-sensitive products within the required temperature range is not always easy. Medicines may be exposed to heat during delivery, frozen food can begin to thaw in transit, and poorly designed packaging may fail to maintain the desired conditions for long enough. These issues can affect product quality and lead to unnecessary losses.
Phase change materials (PCMs) can help manage temperature changes during storage and transportation. However, choosing a PCM is not simply about finding a material with the right temperature rating. Its performance also depends on how it is prepared, the packaging in which it is used, and the conditions it faces during use.
What Is PCM and How Does It Work?
A phase change material (PCM) stores and releases thermal energy as it changes between solid and liquid states. It absorbs heat as it melts and releases heat as it solidifies, helping reduce temperature fluctuations.
For example, a PCM pack placed inside an insulated shipping box can absorb some of the heat entering the package. This helps the contents stay within the desired temperature range for longer, provided the material and packaging are suitable for the application.
PCMWALA offers PCM solutions for different temperature requirements, with materials available across a range of approximately -33°C to +55°C. The right grade depends on the intended use and the conditions that need to be maintained.
What Should You Consider Before Selecting a PCM?
Two PCM products may look similar but perform differently in an actual application. Before choosing one, consider the following factors.
The Temperature Your Product Needs
Start by identifying the temperature limits of the product you want to protect. Frozen food, pharmaceutical products and biological samples do not necessarily require the same conditions.
The PCM’s phase-change temperature should be appropriate for the intended application. Choosing a grade simply because its temperature rating looks close to your target can lead to poor results.
Check the manufacturer’s technical datasheet and consider the temperature inside the package, not just the temperature outside it.
How Long the Temperature Must Be Maintained
A package used for a short local delivery has different requirements from one travelling across several cities over two or three days.
If a shipment regularly becomes too warm before reaching its destination, the problem could be insufficient PCM, poor insulation or a longer journey than the packaging was designed to handle.
Look at the complete transportation process, including loading, storage, transit and possible delays. This will help establish how much thermal protection the system needs.
Thermal Storage Capacity and Packaging
A PCM’s latent heat capacity describes how much energy it can absorb or release during its phase change. This helps determine the quantity required for an application, but it is not the only factor that matters.
The amount of PCM needed also depends on the product load, container size, insulation and surrounding temperature. Even a suitable PCM may fail to provide the expected holding time if heat enters the package too quickly.
For demanding applications, test the complete packaging arrangement before using it for regular shipments.
Where Can PCM Be Used?
PCM is useful in several industries where temperature fluctuations need to be managed. The material should always be selected according to the requirements of the specific application.
Pharmaceutical and Vaccine Transportation
Medicines and vaccines can be sensitive to temperature changes during storage and delivery. If a shipment moves outside its permitted temperature range, product quality may be affected.
PCM can help maintain suitable conditions inside an insulated shipper. However, the selected material must match the product’s temperature requirements, and the packaging arrangement must be tested.
Follow the manufacturer’s conditioning instructions and use appropriate temperature monitoring. This helps identify whether the system maintains the required conditions throughout the journey.
Frozen Food and Cold Chain Logistics
Frozen food, ice cream and other temperature-sensitive products need protection from external heat during transportation. If the packaging cannot provide enough thermal protection, the products may begin to thaw.
A suitable sub-zero PCM can absorb heat entering an insulated container and help maintain the required conditions.
PCMWALA’s IN23 PCM technical datasheet provides product-specific information for evaluating its suitability. Before selecting this grade, check its documented phase-change characteristics and confirm that they match your application.
Buildings and HVAC Systems
Temperature fluctuations are also a concern in buildings. Sunlight, outdoor weather, electrical equipment and occupants can all contribute to changes in indoor temperature.
When incorporated into a suitable building or thermal-management system, PCM can absorb excess heat and release stored energy as conditions change. This may help moderate temperature variations, depending on the design.
The results depend on the PCM’s phase-change temperature, insulation, ventilation and building conditions. PCM should be considered as part of the overall thermal design rather than a complete replacement for heating or air conditioning.
Common PCM Problems and What You Can Do About Them
Even when a PCM is suitable for an application, problems can arise if the material or packaging is not used correctly. Understanding the possible causes makes troubleshooting easier.
Why Does PCM Melt Too Quickly?
If a PCM pack melts sooner than expected, excessive heat may be entering the container. The quantity of PCM may also be insufficient for the journey, or the insulation may not be providing enough protection.
Start by checking the packaging for gaps, damaged seals and weak insulation. Then review the transportation duration, surrounding temperature and amount of PCM used. Increasing the quantity may help in some situations, but the underlying cause should be identified first.
Why Is the Product Becoming Too Cold?
Sometimes a shipment becomes colder than intended, even when the aim is simply to keep it cool.
This can happen when the selected Phase Change material is unsuitable for the product’s temperature limits or when the packs are positioned in a way that creates localised cold spots.
Review the PCM specifications and its placement inside the container. Where necessary, use a suitable separation layer between the packs and the product. Test the revised arrangement to ensure the contents remain within their permitted temperature range.
Why Do Some Shipments Perform Better Than Others?
If one shipment arrives in good condition while another experiences temperature fluctuations, the packing process may not be consistent.
Differences in PCM conditioning, pack quantity, container assembly and ambient conditions can all affect performance.
A practical solution is to standardise the preparation process. Make sure staff follow the same instructions, use the correct amount of PCM and check that the packaging is assembled properly. Temperature loggers can help reveal when conditions begin to change
Why Does the PCM Not Last as Long as Expected?
Shorter-than-expected holding time may result from incomplete conditioning, insufficient thermal capacity, excessive heat entering the container or an underestimated journey duration.
Check the manufacturer’s preparation instructions and review the temperature records from the shipment. These records can help determine whether the problem relates to the material, packaging or operating conditions.
How to Use PCM More Effectively
Before putting a PCM system into regular use, work through these practical steps:
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Define the temperature limits. Know the minimum and maximum temperatures the product can tolerate.
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Review the journey. Consider travel time, outside temperatures, handling and possible delays.
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Select a suitable grade. Compare the required temperature with the PCM’s technical specifications.
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Prepare the material correctly. Follow the manufacturer’s conditioning instructions instead of assuming every PCM requires the same process.
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Check the packaging. Review insulation, container seals, pack placement and PCM quantity.
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Monitor the temperature. Use suitable temperature loggers during representative trials.
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Make adjustments based on evidence. If the system fails to maintain the required conditions, investigate the cause before changing the material or packaging.
This approach is useful for students learning about thermal management as well as professionals responsible for packaging, storage and transportation.