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

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.