
Temperature Mapping study is a process to study and analyze the temperature distribution inside a room. This is mainly applicable for pharma industry for storage of medicines. We carry out temperature mapping study for storage areas and vehicles used for storage and transportation of temperature sensitive goods.
Typically such items are medicines, vaccines etc. Other terminologies used are Thermal mapping study, temperature distribution study etc. If you need to study humidity levels, then we carry out a temperature & humidity mapping study.
We have been carrying out temperature mapping study for past many years across all Asian, African and European countries. This article explains guidelines for carrying out complete temperature mapping study. Please check our VIDEO below for more information on Temperature Mapping.

Please listen to our PODCASTThere are special forms of drugs and vaccines, which we should store and transport at certain controlled temperatures. Majority of these drugs and vaccines are under two categories; those that need storage between 2°C to 8°C and the other is between 15°C to 25°C. It is essential for the effectiveness of the medicines to have these restrictions. If the drug or vaccine is going above these temperature limits, the medicinal value might be gradually lost. More importantly, the goods will no longer show any indication that it does not have the full medicinal properties. In such a case, the ultimate distributor and the person will not know the effectiveness of the medication. Pharma companies store these items in warehouses, controlled rooms or refrigerators.to understand Temperature Mapping Study.

Why Temperature Mapping Study is important?
In case you are involved in manufacturing, transportation, storage or distribution of drugs and vaccines, you know the importance of keeping the drugs in controlled temperature and humidity conditions. This article will give in-depth details about temperature mapping study. In all those cases your medication storage is inside an enclosed place. These will include probably a warehouse, cold room, temperature managed van, reefer truck, fridge, insulated containers etc. After production of the medicine, it goes through various transportation and storage areas until it reaches the end-user. If the medicine is not stored properly, the medicinal values will be completely lost. As an example, a medicine manufacturer recommends that a particular medicine should always be kept between 2 to 8 °C. After the medicine leaves the factory there are various agencies involved such as the international transporter, a regional distributor, a local transporter, a local distributor etc. All these parties should keep this medicine within the specified temperature limits only. If the medicine undergoes temperature variations in any of these agencies during any stage of storage or transportation, it will affect the quality of the medicine.
- How does a 3rd party like your supplier or auditor can check whether the complete controlled room is always maintaining the correct temperature at all points?
- How will you make certain that the display at the front door is precise in relation to the corresponding sensor?
- How do you know about the variations whilst a door is opened? The sensor is probably a long way far from the door and therefore might not reflect the real temperature at many points. However, certainly, it happens that the vicinity near the door suddenly goes above 8°C.
- How do you know what are the variations happening inside the room when power fails?
What is Temperature Mapping Study or Thermal Mapping Study?
As an example, we will consider a temperature-controlled van which is used to transport medicine between 2 and 8 °C. The cooling unit is generally on one corner of the cargo compartment of the van. A control unit mounted inside the driver cabin the temperature inside the cargo compartment. We can set the control unit at a particular temperature eg. 5°C and the temperature inside the cargo chamber. We assume that the temperature inside the van is around 5°C at all times. However, there are various other parameters affecting the uniform distribution of the temperature inside the cargo chamber. Even when the cargo chamber is completely empty, the entire area of this chamber may not be able to maintain a uniform temperature distribution within 2 and 8°C. eg. The corner far away from the cooling unit may reach a temperature higher than 8°C, because of improper air circulation. Another area near the cooling unit may reach a temperature below 2°C at certain times. Both these conditions are harmful to the medicine and will affect its efficacy.
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How to carry out Temperature mapping study?
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Method for carrying out a temperature mapping study
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- Empty test - Analyzing the readings in an empty condition. This is to check whether the room maintains the temperature when the room is completely empty.
- Partial Load test- Analyzing the readings when 60% of the area is loaded with medicines. This is to check whether the room maintains the temperature when the room is almost 60% full. Basically, the standards specify that the tests have to be done under two loaded conditions. So apart from empty test and full test you can decide a percentage as per your regular usage. If you feel that your general usage is with 75% loads, then it is better to carry out the test under 75% load instead of 60% load. If the client does not have any specific requirements, we carry out the tests at 60^ loaded conditions.
- Full load test - Analyzing the readings when the area is loaded completely. This is to check whether the room maintains the temperature when the room is 100% filled with medicines.
- Door opening test - We have to open the doors during each of the above tests to analyze the variations inside the room. Depending on the normal usage pattern, at least 3 different durations have to be tested. Eg. for a cold room, we have to test with one-minute door opening, 3-minute door opening and 5-minute door opening. We might carry out a 10-minute door test also to decide what is the maximum period for which temperature remains within the limits. The purpose of this test is to find out how long the operators can open the door during normal operations.
- Power failure test - In case power fails, we would like to know how long the temperature remains within limits. In order to study this, we have to close the doors and switch off the power. The purpose of this test is to find out how long the medicines are safe inside the area once power fails. This helps you to write an SOP (Standard Operating Protocol) for the actions to be taken in case of a power failure.
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- Start-up test - When you are starting up the cooling unit, you would like to know how long it will take to reach and stabilize at the required temperature from the ambient temperature. This test is known as start-up test. This is especially important for vans, trucks, active boxes etc. which requires frequent switching on and off. If you have a new cold room or warehouse it is advisable to carry out this test. Once you are fully operational, it is difficult to carry out this test, since you will have real medicines inside the room.
- Recovery test is the test to determine the time required to attain and stabilize the specified temperature after a door opening test. The purpose is to specify the time gap between two door openings.
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What is temperature and humidity mapping study and do I need to do the same?
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What is the recommended relative humidity for storage of medicines & pharma goods?
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Why the cold room or walk-in freezer has very high humidity?
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Why the cold storage room has excess ice formation?
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Please listen to our PODCASTfor more information on Temperature Mapping Study.

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How can I reduce the humidity of medicine storage cold room or warehouse?
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What is the sampling interval for a temperature mapping study?
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- The sampling interval for cold rooms is generally 3 minutes. This means the data logger will record the temperature and humidity every 3 minutes. We do not recommend sampling interval above 3 minutes for cold rooms. Since the temperature range is very narrow between 2-8 Degrees, if we keep a higher sampling interval it will not indicate real variations. Eg. If we keep the sampling interval as 5 minutes, it is possible that the temperature will go above 8°C and come back within 5 minutes. If you are keeping extremely sensitive medicines, we recommend keeping a sampling interval of 1 minute. Otherwise, 3 minutes interval is fine. Humidity does not fluctuate very fast, but temperature fluctuates very fast.
- We recommend sampling interval for a warehouse as 10 minutes or 15 minutes. For a warehouse, the temperature range is wide between 15 to 25°C. Also, temperature rise or fall is a slow process. Hence, a sampling interval of 15 minutes also is fine.
- We recommend sampling interval for a van as 3-minute intervals for the same reason as that of a cold room. The fluctuations inside vans are very frequent and hence we do not recommend a sampling interval higher than 5 minutes.
- For reefer trucks transporting goods for a longer duration, the temperature is more stable since there will not be frequent door openings. Hence, the sampling interval between 3 to 5 minutes will be enough.
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What are the details required form the client for commencing mapping study?
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- For warehouses and cold rooms, we require the size of the room including length, width and height. Also, we require the details of the cooling equipment and a layout drawing of the area including the location of the racks.
- For vans and refers, we require the size of the van, model and type of the van and the details of the cooling units. If the van has multiple compartments, we require the details of each of those compartments.
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What is the total duration of temperature mapping study?
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- Warehouse: We recommend a total duration of 10 to 14 days. This test will be continuous and will not disturb your normal operations.
- Cold rooms: We recommend a total duration of 3-4 days. During this period, we will carry out all the tests including door opening, power failure etc. During these tests, there will be limitations on normal operations. Hence we provide a schedule in advance so that the client can plan accordingly.
- Vans for local distribution: We recommend a total duration of 2 -3 days. We will carry outdoor opening, power failure etc. during this period. The vehicles have to be completely free during the entire period.
- Reefer trucks for long transportation: We recommend a total duration of 3-4 days. The client cannot use the truck during this period at all.
- Active boxes: We recommend a total duration of 3-4 days. The client cannot use the boxes during this period at all.
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What is the sequence of activities for a temperature mapping study?
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- Start-up test to determine the time required to attain and stabilize at the desired temperature.
- Empty load test to analyze the performance of the asset under empty conditions. Power failure tests and door opening tests are not essential during this period since it has no practical value. However, we sometimes carry out the tests for critical analysis to compare the values with other tests.
- Partial load tests to analyze the temperature and humidity distribution when the area is loaded partially. As explained earlier, if you have particular conditions you can decide the percentage. Eg. If you generally load your cold at 40%, it is preferable to carry out the tests at 40%. If you have no particular requirement, we carry out the test at 60%.
- We carry out at least 3 different door opening tests and recovery tests during the partial load test.
- At the end of the partial load test, we carry out power failure tests to determine how long the temperature will remain within limits in case of a power failure.
- After completing the above tests, we carry out a full load test to determine the performance during a fully loaded condition.
- Again during the above test, we carry out 3 separate door opening tests and recovery tests.
- Upon completion of the full load test, we once again carry out a power failure test similar to that of the partial load test.
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What loading conditions to be tested during temperature mapping study?
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What are the normal reasons for the failure of assets?
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- Cold rooms – High humidity is one major reason for the failure of cold rooms. Also, the temperature distribution across different areas may not be uniform. Many times, the temperature is shown in the display of the cooling unit may not be actually representing the temperature inside the cold room. It is also possible that the calibration of the display unit is not proper, causing the error. For exact calibration of this display, the calibration company should inject different currents into this display and check the accuracy. Many companies check the temperature at the sensor inside the cold room and compare the results with that of the display. This method is less accurate than the previously recommended method.
- Warehouses – For warehouses, high humidity can be a reason for failure in countries having high humidity. Another cause is that the temperature setting may not be proper. The controller will be showing the temperature at some corner of the warehouse. But the actual temperature across the warehouse will be totally different. The next cause is generally entry of direct sunlight through windows.
- Vans – The small distribution vehicles are tough to pass especially in hot countries. One of the main reasons is not having a properly calibrated controller as explained for cold rooms. The second reason is not having proper lower limit and upper limit cut off for the cooling unit. The cooling unit supplier can do this programming.
- Reefer trucks – Performance of these cooling units are better than those of vans. The main reason for failure is not having proper airflow, especially when the truck is fully loaded. The cooling unit will be at one end of the truck. The airflow to the other end may not be proper. This happens especially if the truck does not proper internal ducting. The calibration of the controller is applicable for reefers as well.
- Refrigerators – For refrigerators, the main reason for failure is the recovery period after a door opening. The inbuilt controller and the sensor positioning has to be proper.
- Cooling boxes – For cooling boxes, the cooling unit is extremely small and generally is able to perform well in the small area inside the box. Generally, we see a higher failure rate in case of old boxes, which are in their second or third year of operation.
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Please listen to our PODCASTfor more information on Temperature Mapping Study.
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What will be the contents of the mapping study reports?
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- The temperature and humidity distribution analysis charts for each test.
- Individual readings of all data loggers.
- The layout drawing of the area including the positioning of racks. The client should not change the shelves layout after conducting the temperature mapping study. If you have to change the racks, you have to carry out a fresh mapping study after changing the racks.
- The report will contain recommendations for including in the SOP for regular operations.
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How long is the validity of a mapping study report?
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- Cold rooms and warehouses: We recommend to repeat the mapping study once in every 3 years.
- Vans & Reefers: We recommend to repeat the mapping study once in every 2 years. This is because the performance is highly dependent on the age of the vehicle and the cooling units.
- Cooling boxes: We recommend to repeat the mapping study once in 12 to 18 months especially for 2-8 Degree C boxes. We have noticed that by the second year, the performance of the boxes deteriorates.
- Refrigerators: We recommend to repeat the mapping study once in 2 years.
- Humidity chambers & stability chambers: We recommend to repeat the mapping study once in 2 years.
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How many climatic seasons we should do a mapping study?
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How to select a vendor for a temperature mapping study?
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- Even though the tests are not highly technical, analysis and recommendations require high technical skills. Especially if the tests fail, you will need technical help to analyze the problem. Hence we recommend the client to appoint technical companies having experience in the HVAC system.
- The company should have expertise in multiple disciplines such as dehumidification, cooling systems etc. If the company undertakes complete responsibility of adjusting the cooling units, controlling humidity etc., the client need not worry about the results.
- The company should have international exposure. This way they will have better knowledge compared to a local company. The auditors come from different parts of the world with different practices. Hence you will benefit by appointing an international company for your mapping study.
- In case the test fails, the company should be able to give you specific corrective action including any design calculations etc. Also, you have to seek a retest in case the test fails.
- Their report should have recommendations to include in your SOP (Standard operational practices/protocol).
- Some of your regulations will require that there should be interlocking of doors for your warehouses. This means that it should not be possible to operate two different sets of doors simultaneously. We will be able to complete provide such systems if required.
- Some other requirements call for the local siren and phone call alerts in case of temperature excursions. Our engineering team will be able to provide such solutions.
- If required the temperature mapping company should be able to prepare the complete SOP for you.
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How to prepare an SOP (standard operational protocol) after conducting a mapping study?
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- What should be the temperature setting for the cooling unit?
- What is the ideal door opening time?
- What should be the gap between the two door openings?
- Is there any area, which is susceptible to temperature variations? In such a case, the client has to isolate those areas from keeping highly sensitive goods.
- Are there any other precautions required in case of extreme weather conditions?
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What are the points a client has to implement from a mapping study?
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- Make sure to adjust the temperature of all the controllers in line with the recommendations in the report.
- Install the temperature and humidity monitoring and alert systems.
- Modify existing SOP/write an SOP incorporating the recommendations of the report.
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What auditors generally want to see in a report?
- Is the present layout exactly as indicated in the temperature mapping report? If there are major changes in the layout including the racks, a new mapping study is required.
- Whether there is a continuous monitoring system as per the hot and cold points indicated in the report?
- What are the highest and lowest readings recorded and whether they are very close to the upper and lower limits? Even if the mapping study has passed, these points will be a matter of concern.
- Whether the controllers have set points indicated in the report?
- Whether the client has implemented the recommendations indicated in the mapping study report?
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How to install temperature & humidity sensors as per the mapping report?
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What are the recommended requirements for a temperature & humidity monitoring system?
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- It should be possible to adjust the sampling frequency from 1 minute to 15 minutes.
- The system should continue recording even in case of a power failure without loss of data.
- The system should generate phone call and SMS alerts to at least 4 people.
- The system should continue calling until one of the operators acknowledges the phone call by pressing a separate button on the phone. The system should continue calling all the people in case nobody acknowledges the call.
- The phone call alert system should be preferably through a SIM card instead of a cloud-based system. This ensures more reliability. In the other case, there will always be a certain amount of uncertainty because it has to pass through multiple networks and software.
- The system should work even in case of network failure.
- It should be possible to connect a local alarm or hooter. In such a case, local operators will get the alert immediately.
- It is preferable to have a system without annual software charges.
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Is Mean Kinetic Temperature acceptable for a mapping study?
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Please listen to our PODCASTTemperature Mapping Study only gives the behavioural pattern inside the area. A Qualification Study carries out a detailed analysis of the area. This is to prove that design, installation and operation are in accordance with the desired results. Eg. Consider that a complete set of qualification study is carried out for a cold room. It analyses that the whole set of the cold room and associated equipment such as cooling units are designed, installed and operated properly. The result should be that it will always achieve a temperature between 2 and 8 °C. Such tests are not part of a mapping study explained in the previous section. The company which carries out a qualification study needs to have expertise in mechanical and electrical engineering since this involves a series of electrical and mechanical tests. The Qualification Study generally involves the following procedures:for more information on Temperature Mapping Study.
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- Design qualification and verification to ensure that the asset and its equipment are designed to achieve the desired results. This process will involve verifying the design process of the asset. After verifying the design, it has to be verified that the installed equipment and the asset are as per this design documents.
- Installation qualification (IQ) and verification is carried out next to verify that all the equipment and the asset itself are installed as per the design document and as per the installation instructions of the respective manufacturers
- Operational qualification (OQ) and verification to verify that the equipment is operated as per the recommended methods of the manufacturers.
- Performance Qualification study (PQ) to evaluate the performance. Temperature and humidity distribution study is part of this Performance Qualification.
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- Temperature mapping & qualification protocol for pharma Cold Rooms - VIEW | DOWNLOAD
- Temperature mapping & qualification protocol for Cool boxes - VIEW | DOWNLOAD
- Temperature mapping & qualification protocol for Vans - VIEW | DOWNLOAD
- Temperature mapping & qualification protocol for pharma Warehouses - VIEW | DOWNLOAD
- Temperature mapping & qualification protocol for Reefer trucks - VIEW | DOWNLOAD
- Temperature validation protocol for distribution vans - VIEW | DOWNLOAD
- Temperature validation protocol for refrigerator - VIEW | DOWNLOAD

Our services on temperature mapping study & Qualification
- Service Type: Temperature Mapping Study, qualification & Validation
- Areas Served: The United States of America, United Kingdom, Germany, France, The United Arab Emirates, Saudi Arabia (Riyadh, Jeddah, Dammam, Jubail), Qatar, Oman, Bahrain, Kuwait, Kenya, Tanzania, Ethiopia, Rwanda, Uganda, Egypt, Jordan, Lebanon, India, Pakistan.
- Service Offer: Temperature Mapping Study & Qualification, Humidity Control Systems, Temperature Monitoring Systems for Warehouse/Cold Stores/Vans/Boxes, Economic & Energy Saving Walk-In Cold Stores.
- Provider Name: VackerGlobal, 92438, Deira, Dubai, United Arab Emirates. Tel: +97142661144
- Service Description:
- Temperature mapping study and qualification of warehouses.
- Temperature mapping study and qualification of cold rooms and walk-in freezers.
- Temperature mapping study and qualification of medical refrigerators.
- Temperature mapping study and qualification of passive boxes for medicines.
- Temperature mapping study and qualification of active boxes for medicines.
- Temperature mapping study and qualification of reefer trucks.
- Temperature mapping study and qualification of refrigerated vans.