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Reproducing Cold-Chain Conditions in Real Time Using a Controlled Peltier-Based Climate System

Garrido-López, Javier M., Ramallo-González, Alfonso P., Jiménez-Buendía, Manuel, Toledo-Moreo, Ana, Torres-Sánchez, Roque·2025·Sensors
DOI 10.3390/s25216689
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Abstract

Temperature excursions during refrigerated transport strongly affect the quality and shelf life of perishable food, yet reproducing realistic, time-varying cold-chain temperature histories in the laboratory remains challenging. In this study, we present a compact, portable climate chamber driven by Peltier modules and an identification-guided control architecture designed to reproduce real refrigerated-truck temperature histories with high fidelity. Control is implemented as a cascaded regulator: an outer two-degree-of-freedom PID for air-temperature tracking and faster inner PID loops for module-face regulation, enhanced with derivative filtering, anti-windup back-calculation, a Smith predictor, and hysteresis-based bumpless switching to manage dead time and polarity reversals. The system integrates distributed temperature and humidity sensors to provide real-time feedback for precise thermal control, enabling accurate reproduction of cold-chain conditions. Validation comprised two independent 36-day reproductions of field traces and a focused 24-h comparison against traditional control baselines. Over the long trials, the chamber achieved very low long-run errors (MAE≅0.19 °C, MedAE≅0.10 °C, RMSE≅0.33 °C, R2=0.9985). The 24-h test demonstrated that our optimized controller tracked the reference, improving both transient and steady-state behaviour. The system tolerated realistic humidity transients without loss of closed-loop performance. This portable platform functions as a reproducible physical twin for cold-chain experiments and a reliable data source for training predictive shelf-life and digital-twin models to reduce food waste.

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Cited by 3

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Metadata

Authors
Garrido-López, J. M., Ramallo-González, A. P., Jiménez-Buendía, M., Toledo-Moreo, A., & Torres-Sánchez, R.
Venue
Sensors
Publisher
MDPI AG
Published
2025-11-01
Volume
25
Issue
21
Pages
6689
ISSN
1424-8220
DOI
10.3390/s25216689
Cited by
3
Language
en
Licence
creativecommons.org/licenses/by/4.0/ (vor)
Funders
  • Ministry of Science, Innovation, and Universities (PRTR-C17.I1)
  • FPU programme (FPU23/00186)
  • Comunidad Autónoma Región de Murcia
  • “Prueba de Concepto” programme (22267PDC-23)

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CoChat. (2026). Citation check: Reproducing Cold-Chain Conditions in Real Time Using a Controlled Peltier-Based Climate System. https://app.cochat.ai/papers/10.3390/s25216689
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Garrido-López, J. M., Ramallo-González, A. P., Jiménez-Buendía, M., Toledo-Moreo, A., & Torres-Sánchez, R. (2025). Reproducing Cold-Chain Conditions in Real Time Using a Controlled Peltier-Based Climate System. Sensors. https://doi.org/10.3390/s25216689

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