Thermocline Thermal Energy Storage is a well-competitive device to increase the usability of solar concentrated power and process heating plants worldwide. In the device, the phase change material (PCMs) is used as an energy storage filler material, and the heat transfer fluid (Therminol-VP1) is used as an energy transfer element. The phase change materials are encapsulated with high conductive encapsulation material, and the thickness of the encapsulation material is crucial in the energy storage system. The lower encapsulation thickness may lead to failure, which is a serious issue. The failure (i) affects the charging and discharging characteristics, (ii) reduces the storage efficiency, (iii) spoils the heat transfer fluid, and (iv) increases the maintenance cost. However, it reduced the charging time and behaved vice versa for the higher encapsulation thickness. Additionally, higher encapsulation thickness increases the structural weight, as well as the cost of the tank. The Stainless Steel (SS316L) is used as an encapsulation material to encapsulate the five PCMs such as NaNO3, NaNO2, KNO3, Solar Salt (60%NaNO3+40%KNO3), and Hitec Salt (7%NaNO3+40%NaNO2+53%KNO3) with different thickness in the range of 1-2mm. The displacement and stress correlations are developed with the number of encapsulated PCMs for the energy storage tank H/D=2-4. Further, the developed spherical encapsulation encapsulates the synthesised hitec salt phase change material. The performance and melting dynamics of the hitec salt are studied with various flow rates of heat transfer fluid. The corresponding temperature distributions inside the encapsulation are measured with a temperature detector, and it found that the energetic efficiency of the 0.060m size of the encapsulated spherical capsule is 92.73% for the period of charging time of ~ 30 minutes and found that the liquid fraction is 1. The average efficiency of the capsule is 53.28%, and the corresponding liquid fraction is nearly 0.31, which can be reached within the first 15 minutes of charging time. The developed encapsulated hitec salt phase change material is more suitable to commercialise a thermocline thermal energy storage system in medium-temperature process heating industries such as food, dairy, pharmaceutical, textile, and leather processing industries.