The development of a two-stage Pulse Tube Cryocooler (PTC) which produces a no-load temperature of similar to 3 K and delivers a refrigeration power of similar to 250 mW at 5 K is reported in this work. The system uses stainless steel meshes along with lead (Pb) granules and combinations of Pb, Er3Ni and HoCu2 in layered structures as the first and second stage regenerator materials respectively. With Helium as a working fluid, the pressure oscillations are generated using a 6 kW water-cooled Helium compressor along with an indigenous rotary valve. Different configurations of pulse tube systems have been experimentally studied, by both varying the dimensions of pulse tubes and regenerators as well as the second stage regenerator material composition. The pulse tube Cryocooler has been numerically analyzed by using both the isothermal model and the model based on solving the energy equations. The predicted refrigeration powers as well as the temperature profiles have been compared with the experimental results for specific pulse tube configurations. (C) 2008 Elsevier Ltd. All rights reserved