Think of the box

Compiled by Eamonn Ryan

Rethinking refrigerated transport for a smarter cold chain.

In the refrigerated transport and broader cold chain sector, boxes dominate our landscape – literally and figuratively. From insulated vans and trailers, to refrigerated warehouses, supermarket chillers, domestic fridges and even the packaging of perishable items, we live in a world of cold boxes. And yet, while we pour time and resources into protecting the contents of these boxes, perhaps the answers we seek lie in the box itself.

Consider the journey of a perishable item, such as a fresh food product, through the cold chain. In a simplified model, we apply

• On-site cooling in the field: produce is gathered and stored in refrigerated boxes
• Factory intake: transported to a refrigerated facility for processing
• Outbound transport: packaged goods leave in refrigerated trucks
• Distribution centre: stored again in refrigerated warehouses
• Retail delivery: shipped to supermarkets in another round of refrigerated transport
• In-store cooling: held in chilled display units or cold rooms
• Home delivery: sent in refrigerated vans
• Domestic storage: finally ends up in a household refrigerator

The current system is built on ensuring goods remain at a safe temperature throughout their journey, but at what cost? We invest immense energy into cooling goods, only to repeat the process again at the next stage. In some cases, we’re refrigerating simply because it’s standard practice – not because it’s essential in that moment.

This brings us to the heart of the issue: Are we refrigerating out of necessity or out of habit?

It’s time to reframe the question – not how we protect what’s inside the box, but how the box itself can do more. This shift in thinking could unlock new efficiencies, reduce emissions and challenge the status quo in cold chain design and logistics.

 

Energy retention over energy addition

One emerging concept is to preserve the cooling energy already invested into goods, rather than constantly reapplying it. This means:

• Smarter insulation: improving the thermal efficiency of containers to prevent temperature loss, rather than compensating for it with more energy
• Thermal monitoring: equipping boxes with sensors to track actual product temperature, not just ambient air
• Energy piggybacking: reusing or redirecting cooling energy from high- capacity sites like cold stores to support transport or last-mile nodes
• Strategic refrigeration: cooling only when and where it’s absolutely needed, rather than relying on redundancy throughout the chain

There are global innovations, some centuries old and others tech-enabled, that are being rediscovered and refined. These include phase-change materials, vacuum panels, solar-assisted systems and passive cooling technologies that reduce or even eliminate the need for powered refrigeration in certain applications.

There’s a growing argument to be made for right-sizing refrigeration based on real data and usage patterns, rather than legacy standards or over-engineering.

At its core, the cold chain was never about technology for technology’s sake. It was – and still is – about preserving the quality and safety of products, reducing waste and maintaining trust with consumers. But somewhere along the way, it has become increasingly complex, carbon- intensive and fragmented.

By focusing back on ‘the box’ – its construction, insulation, purpose and monitoring – we return to the fundamentals of cold chain logic. A smart, efficient box could reduce reliance on diesel-powered refrigeration units, cut synthetic refrigerant use and help meet global sustainability goals.

 

A Serco guide to cost savings for operators in the cold chain

Truck and trailer body building company Serco has some top tips to help improve the transport of perishable goods and boost fleet efficiency.

CEO Clinton Holcroft says: “Transporting perishable goods is a high-stakes operation. Whether you’re moving fresh produce, pharmaceuticals or frozen foods, maintaining optimal temperature and minimising wear and tear on refrigerated trucks and trailers are critical.”

“Here is our collection of tips to help logistics and retail fleet managers improve thermal performance, reduce fuel costs, and extend vehicle lifespan.”

1. General maintenance

• Keep tyres correctly inflated to reduce fuel consumption and extend tyre life
• Always check the fully laden weight before trips to avoid fines and excessive wear
• Balance the load to prevent uneven tyre wear and mechanical strain
• Roads in poor condition can put wheel alignment out – check regularly to maintain tyre health
• Clean filters, check refrigerant levels and maintain service schedules to counter fuel-hungry cooling units

2. Refrigerated body specification – build for performance through use of:

• High-density polyurethane (PU) foam panels boast superior insulation compared to polystyrene, with lower water absorption and faster cooling to set point
• With durable panel facings, coated steel or high strength composite facings resist impact damage and extend body life
• PVC strip curtains retain cold air during frequent door openings
• Insulated bun partitions isolate compartments to reduce cooling load and fuel usage
• 60/40 door splits minimise cold air loss during partial unloading

3. Vehicle body maintenance protects your investment

• Corner capping: Maintain seals to prevent water ingress from tree strikes or road debris
• Seal holes promptly: Even small punctures can compromise insulation and hygiene
• Panel damage: Cracks allow water into insulation, reducing thermal efficiency and increasing fuel use. Reinforce with internal scuffing or steel panels
• Floor integrity: Prevent damage from pallet dragging and overloading to avoid cold air leaks and contamination risks
• Door seals: Multi-leaf seals are best for preventing cold air escape – inspect and replace regularly

4. Operational best practices and smart habits that save fuel

• Stabilise internal temperature before loading to protect product integrity
• Load at the correct temperature as the fridge maintains temperature – it doesn’t cool warm goods efficiently
• Fridge-off during loading – this prevents cold air from being blown out when doors are open.

 

Bonus tips for fleet managers

• Telematics integration employs real- time monitoring to track temperature, door openings and fridge performance
• Driver training educates drivers on best practices for loading, unloading and fridge operation
• Route optimisation reduces travel time and fuel usage with smart routing software
• Adapt fridge settings and maintenance schedules based on ambient temperature changes

“Efficient refrigerated transport isn’t just about keeping goods cold – it’s about smart maintenance, thoughtful design and operational discipline. By implementing these tips, fleet managers can reduce costs, improve product safety and extend the life of their vehicles,” says Holcroft.

 

Quality lubricants are critical for optimal efficiency in cold storage truck fleets

The most critical aspect for cold storage truck fleets is temperature control. Goods must be transported under optimal temperature conditions at all times, ensuring integrity of goods. “It is a delicate balancing act as the temperature is dictated by the cargo carried and can vary from -25°C to +25°C,” notes Andy Weddell, local segment lead: commercial vehicles at FUCHS Lubricants South Africa.

“The truck itself needs to run efficiently and effectively to ensure no downtime and potential loss of goods. One would also need to consider if the refrigeration unit runs separately to the truck. In some cases, the compressor runs off the vehicle’s engine and from a separate source in others,” explains Weddell.

While extreme cold temperatures do not really have a huge impact on refrigerated truck operations, using quality lubricants in both the vehicle and refrigerated trailer is integral to a fleet’s operating capacity, allowing it to operate over a wide temperature range.

When it comes to transmission lubrication, the more efficiently a transmission runs, the better the truck operates. A high-quality Automatic Transmission Fluid (ATF) contributes to fuel efficiency and extended equipment life.

Looking at general advice for cold storage truck fleet operators, Weddell says: Monitor the condition of your oil through regular oil samples, hence adopting a more proactive approach; ensure you conform to the oil drain interval prescribed by the transmission manufacturer and the requirements and approvals of the OEM. “This is absolutely key to your transmission’s lifespan.”

Due to technological advances, the entire refrigerant market is moving away from mineral-based products to synthetic lubricants.

 

Thermo King launches ecomode to cut fuel use in advancer trailer units

Thermo King, a brand of Trane Technologies, has introduced ECOmode, a new operating feature for its Advancer trailer refrigeration units. The mode is designed to help fleet operators reduce fuel consumption by up to 50% compared to continuous operation, while maintaining tighter temperature control than the existing start-stop CycleSentry mode.

ECOmode expands the operational flexibility of the Advancer range by optimising performance based on the sensitivity of the cargo and delivery profile. It limits temperature deviation from the set point and uses sequential airflow to protect cargo, making it suitable for goods that require consistent, though not ultra-tight, temperature control.

With the addition of ECOmode, Thermo King now offers three operating modes for Advancer units: Continuous, CycleSentry, and ECOmode. According to the company, the new mode helps reduce operational costs without compromising cargo safety or regulatory compliance.

“All Thermo King Advancer units offer complete transparency of fuel levels and consumption, accessible both on the unit and remotely via telematics,” says Colm O’Grady, product leader: trailer at Thermo King. “We have introduced ECOmode to give more flexibility and control to fleet managers and help them reduce their operational costs.” CLA

Reference

1. Norman Highnam MInstR | LinkedIn

 

Crickley Dairy elevates cold chain logistics with Serco fleet upgrade Eastern Cape-based Crickley Dairy has completed a major upgrade of its refrigerated transport fleet, marking a milestone in the company’s ongoing growth and commitment to delivering high-quality dairy products across the region. The project, which involved the manufacture and delivery of 11 new 6.5m refrigerated truck bodies, was completed in partnership with leading truck body builder Serco and refrigeration specialists Spheros – all within a tight four-week timeline. The upgrade comes in response to Crickley Dairy’s growing distribution needs and the increasing pressure placed on its ageing fleet, which had become unreliable due to excessive mileage and high maintenance demands. “Some of our trucks had clocked over a million kilometres. We couldn’t deliver reliably, and the cost of constant repairs made it unsustainable. A complete fleet replacement became a necessity, not a choice,” says Crickley Diary CEO John Conway. With consumer expectations rising and product integrity critical in dairy logistics, the company recognised the urgent need for modern, efficient and robust cold chain capabilities.   A tailored, time-sensitive build The agreement with Serco was signed earlier this year, and all vehicles were completed and delivered well within the tight four-week window. Crickley praised Serco’s planning, resource co-ordination and commitment to meeting the deadline without compromising on quality. Each truck features GRP-insulated bodies, with 50mm polyurethane panels rated to maintain temperatures as low as -18°C. The interiors include durable aluminium ‘rice grain’ flooring, expected to extend floor lifespan by up to 10 years, and customised pallet jack storage integrated at the rear door, enhancing hygiene and operator efficiency. “This project was executed flawlessly thanks to strong collaboration between Serco, UD Trucks and Spheros. From chassis integration to refrigeration  and body construction, teamwork and transparent communication made it all possible,” Conway noted.   Next-generation refrigeration with Spheros The trucks are powered by Spheros MT310 refrigeration units, capable of maintaining internal temperatures from +25°C to -25°C. These systems include a two-cylinder diesel engine and a 380V electric standby function, offering both flexibility and reliability for different operating conditions. Key technical specs include: 5kW cooling capacity at 0°C setpoint (30°C ambient) 3kW capacity at -20°C setpoint Three-zone temperature monitoring (front, middle and rear) Real-time tracking via the Carrus system Optimal airflow is ensured by proper pallet spacing during loading, which prevents hotspots and ensures uniform temperature throughout the cargo space – critical for preserving the quality of sensitive dairy products. The benefits of the new fleet extend beyond reliability. Crickley reports improved fuel efficiency, fewer breakdowns and enhanced branding visibility, thanks to sleek new truck- side advertising – something that was impossible on the ageing fleet. “More than just increasing capacity, this upgrade boosts our operational efficiency and reduces our environmental impact. With fewer unplanned repairs and better mileage, we can now reach more markets, more often,” says Conway. The trucks also enhance safety, for both the products and Crickley employees, through updated technology and improved build standards.   From humble beginnings to modern logistics Founded in 1984 by Ken Clark with just five cows and one farmhand, Crickley Dairy has grown into a respected regional dairy brand in the Eastern Cape. The company’s legacy of delivering nutritious, locally produced dairy now enters a new phase, supported by high-tech transport infrastructure. Conway hinted at future expansions: “We are extremely pleased with the outcome of this project. There’s definitely potential for additional fleet upgrades, including our truck tractors used to collect milk from farms.” Environmental considerations were also key in the decision-making process. Crickley selected UD Euro 5 trucks, reducing emissions and aligning with shifting regulatory and consumer expectations around sustainability in logistics. While traditional refrigerants were used for this phase, the company is actively evaluating greener alternatives and advanced technologies for future upgrades. Serco CEO Clinton Holcroft reflected on the project’s success and the potential of the partnership: “We’re proud to support Crickley Dairy’s growth by delivering vehicles tailored to their operational needs. With our Deal Party facility in Gqeberha, we’re well-positioned to provide ongoing support and repairs. We look forward to building on this relationship as Crickley continues its remarkable journey.” Source: Submitted by Crickley Dairy

 

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