Taiyo Kogyo Column
Cold chain logistics optimized‼︎ high performance commercial cold storage boxes (bags) with vacuum insulation
2017.07.07
1. The cold chain required today
*Reference: Japan Frozen Foods Association, April 20, 2017 Preliminary Statistics Data Trends in Frozen Food Consumption
The consumption of frozen food is increasing year by year.
In particular, domestic production of frozen foods has increased rapidly since the end of the Showa period and accounts for the majority of domestic consumption. Cold chain refers to the logistics of distributing products that require low-temperature management while maintaining their quality and keeping them cold, chilled, or frozen from the place of origin to the place of sale, such as a supermarket. In recent years, with the aging of the population and the shift to nuclear families, demand for processed foods, pre-prepared foods, and food service markets has increased, and cold-distributed products have become indispensable in our daily lives. Many people use frozen foods, prepared foods, and medicines sold in convenience stores, supermarkets, and drugstores on a daily basis. It is no exaggeration to say that our lives are supported by the cold chain. From pharmaceutical companies to food manufacturers on the manufacturing side, and from convenience store vendors to supermarket distributors on the retail side, cold chain is needed in a wide variety of industries. In addition, in order to meet the needs of increasingly sophisticated (diversified and upscale) consumers, cold chains are also required to provide a wider range of highly accurate cold management according to the type of product, region, and season.
2. "Commercial cold storage boxes (bags)," an essential tool for cold chain improvement
コールドチェーンの品質、コストを改善には、効率的な商品の保管方法、経路、積層する車など、様々な方法がありますが、その中でも重要な、低温流通管理資材をピックアップして説明します。 低温保冷資材の分類としては、
- For hand handling
- When loading on a basket cart
There are two main types of applications. For products such as frozen foods, which require low temperature control below 0°C of storage temperature,
It is recommended to use a “freezer shipper,” a cold storage box (bag) of a size that can be handled by hand in (1) to improve cold storage efficiency.
[Main uses of frozen shippers
- Frozen and refrigerated food transportation
- Transportation of pharmaceuticals
- Transportation of frozen food for co-op
- Cold storage containers for air cargo
- Transport for home delivery etc…
従来の冷凍シッパーはポリスチレン樹脂を発砲させたフォームを使っています。形状はボード状で、耐圧力があるため、建材用の断熱材としても広く使われている素材です。
しかし従来型の冷凍シッパー以上に、効率的なコールドチェーンを生む「高性能保冷ボックス（バッグ）」があります。以下では「高性能保冷ボックス（バッグ）」について詳しくご説明します。
3. Mechanism of high-performance cold storage box (bag) and vacuum insulation
[Illustration: Vacuum Insulation Panel (VIP)]
Structure of Vacuum Insulation Panel
We have developed a high-performance cold storage box (bag) to reduce shipping costs for 3PL businesses that handle refrigerated and frozen goods.
The high performance cold storage boxes (bags) are supported by a heat insulator called
Vacuum Insulation Panel (VIP).
VIP is used as insulation for freezers that claim to save energy.
4. Development of vacuum insulation material for cold storage box (bag) applications
【図解：発泡ウレタン材によるVIPの被覆方法詳細】
発泡ウレタン材によるVIPの被覆方法詳細
VIPは断熱性能において最も優れている断熱素材の一つですが、価格とVIP保護対策が課題でした。
＊突き刺し等による外部からのダメージにより、VIPに穴が開くと断熱性能が落ちるためです。
We have developed a cost-competitive supplier of VIP insulation.
*We are dealing directly with a manufacturer that produces integrally molded products of urethane foam material and VIP.
弊社で採用している高性能保冷ボックス（バッグ）には、「PUVIP」と呼ばれる発砲ウレタン材とVIPの一体成型パネルが断熱素材として使われています。 真空断熱材の保護材や保護方法に関する課題については、
We have developed a method to completely cover VIP with urethane foam material.
一般的な保冷ボックス（バッグ）には、XPSやEPSのような
建材としても使われる断熱材を使用することが一般的です。
5. 3 cost reductions brought about by high-performance cold storage boxes (bags)
We believe there are three ways to reduce logistics costs by adopting cold storage boxes (bags) with high insulation performance.
5-1. Reduction of distribution costs by reducing the amount of refrigerant (required amount of cold storage materials)
| Conventional Freezer-Shipper | Freezing Shipper with VIP | |||
 |
⇒ |  |
||
| Measured internal temperatures using four cold-storage materials | Under the same ambient temperature conditions as a conventional sipper, the same internal temperature can be achieved with The same internal temperature as a conventional sipper can be achieved with less cold storage material than a conventional sipper. |
そもそも保冷ボックス（バッグ）自体には温度を冷やす能力はありませんので、冷媒と呼ばれる蓄冷材やドライアイスと併用で保冷ボックス（バッグ）を運用します。 保冷ボックス（バッグ）は一度購入すると数年は使用できる優れものですが、
蓄冷材の一部はサイクルの早い消耗品です。 長期的な視点で考えたとき、冷媒量の削減はトータル物流コスト削減に大きく影響します。
5-2. Reduction of logistics costs by improving loading efficiency in transportation vehicles
Comparison of Thickness between Vacuum Insulation (VIP) and General Insulation
When producing cold storage boxes (bags) with the same internal volume, the use of insulation material with high insulation performance makes it possible to make the panels of the cold storage box (bag) thinner than when using insulation material with low insulation performance.
By reducing the outer dimensions, it is expected to increase the efficiency of loading the boxes onto trucks.
Increased loading efficiency may lead to a reduction in the number of trucks.
5-3. Reduction of logistics costs by increasing the amount of goods stored in boxes
保冷ボックス（バッグ）の外寸を固定した場合、断熱パネルを薄くすることにより内容積がアップします。
上記表にもありますとおり、「PUVIP」を使用したタイプの保冷ボックス（バッグ）は同じ外寸法の従来品保冷シッパーと比べ、箱の厚みは半分以下。その結果として、ボックス内容積が約1.5倍に、保冷効率を表す熱還流率も向上します。 また、同じ外寸の保冷ボックス（バッグ）に、より多くの商品を積載することは
It also reduces the amount of cold storage boxes (bags) needed.
断熱性能の高い保冷ボックス（バッグ）を採用し、
物流コストの低減を検討してみてはいかがでしょうか。
If you are interested in high performance cold storage boxes (bags), please contact us. ↓↓↓ You may also read this article.
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