| Written by Constance Stickler
What Makes Reefer Cargoes Unique and Challenging?
Reefers protect temperature-sensitive cargo: they ensure that avocados stay fresh, vaccines remain effective, and ice cream is transported across the oceans frozen and not as a milkshake. These high-tech cool boxes are heroes of global trade but also divas due to their needs. They need precise temperatures, just the correct humidity, and enough air circulation to keep their precious cargo happy.
It's not only about keeping things cool; it's about maintaining a whole series of parameters. For some products, it's just minor deviations from the optimal state that turn high-quality goods into very expensive compost or useless chemicals. In some industries, such as pharmaceuticals, this can mean not only financial damage, it can endanger lives.
Refrigerated transport relies on sophisticated technology and specialist knowledge to ensure smooth operation. Strict international standards, whose compliance must also be precisely documented, are in place to ensure this.
What Are the Common Causes of Non-Compliance in Reefer Operations?
True to its diva reputation, there are a number of factors that contribute to non-compliance:
At the beginning of the journey, reefers must be cleaned and sanitised before the goods are loaded. If this is done inadequately, it is a quick way to fail inspections.
Improper stacking and bracing of pallets can impede airflow and cause temperature fluctuations. Such poor loading practices negate correct reefer settings.
If there is poor documentation of procedures and temperature controls, companies are at risk of non-compliance with their record-keeping obligations, such as those required by FSMA.
The most obvious factor is problems with temperature protocols and maintaining the correct temperature during transit and in ports or depots. This also includes incorrect loading temperatures ("hot loads"), often due to goods being on loading docks for too long.
Equipment failures lead to a whole range of non-compliances. Fluid leaks, air leaks, and faulty components such as compressors, condensers, and evaporators can cause problems maintaining optimal conditions. Old and poorly maintained equipment is more prone to failure, so regular inspections and maintenance are critical to compliance.
Faulty sensors or incorrect calibration can lead to inaccurate temperature readings and missed alerts. This is especially annoying when real-time monitoring is in place, and resulting alarms would allow enough time to save the goods.
Power supply issues, whether due to reefers being unplugged late or accidentally or power outages, can lead to exceedances of required values.
In today's logistics, complex systems and numerous alarm codes must be managed. Human errors are common, such as in configurations or by failing to resolve alarms promptly.
Excessive transit times due to port congestion, deviations or vessel breakdowns can also affect cargo quality and compliance.
How Do Seasonal Peaks Impact Reefer Operations?
The daily logistics routine is challenging enough, but seasonal peaks are the height of the hustle and bustle. Whether it's the rush before various holidays or the madness of the harvest season, demand skyrockets and puts immense pressure on logistics professionals and equipment.
Reefers are flooding the ports, and the abovementioned challenges are becoming even more acute. When deviations from the plan occur, the buffers are really strained and sometimes overwhelmed. For example, generators are often available at ports in addition to the fixed power plugs for the reefers, but of course, the number of these is not endless. However, the longer a reefer has to wait to be connected and monitored, the greater the risk of violations - and ruined cargo.
Most of the peak seasons for reefers are due to harvest seasons. Unfortunately, a large amount of food is still lost during transport. There are very few statistics on exactly how much, but the Food and Agriculture Organization of the United Nations (FAO) estimates that 14 per cent of the food supply is lost, which is $400 billion. (1)
"Wasting food is not only an ethical and economic issue but it also depletes the environment of limited natural resources." states the European Commission in its statement on food waste in the European Union. (2) The problem is indeed more far-reaching than initially assumed, from contributing to greenhouse gas emissions, water waste and soil degradation to productivity loss and food insecurity to landfill burden and biodiversity loss. A lot can still be done, especially during transport, to ensure that products reach their destination safely.
When large reefer cargo volumes are pending, the demand for reefers often exceeds their supply. This means that inferior equipment is put into operation that should actually be sorted out or at least overhauled, which, of course, puts the shipments at risk. The monitoring systems are also put under strain, although the software side is usually not a problem; however, the hardware (especially the transponders connected to the containers) must be available in sufficient quantities.
Now, it becomes clear whether the processes introduced can withstand real-life stress tests. All processes that generally only work halfway can bring operations to a standstill. Seasonal peaks put every aspect of refrigerated container logistics to the test, from resource management to operational precision.
Success lies in preparation: robust systems, demand forecasts that are as precise as possible, and enough flexibility to make operations resilient make the difference between a smooth process and a logistical nightmare.
We will look at what these measures can look like in detail in the next chapter:
How Can You Ensure Compliance with Reefer Cargo Regulations?
Cleaning and Sanitisation of Reefers
To ensure that nothing is forgotten during cleaning, a protocol should first be created that can then be followed for each reefer. Depending on the previous load and level of contamination (nobody wants flowers that smell of fish or cheese), procedures such as sweeping, vacuuming, high-pressure cleaning or steam cleaning are appropriate. When choosing chemical disinfectants, a balance must be maintained: strong enough to eliminate microorganisms and gentle enough not to damage the container. There are also automated solutions: robots that clean the entire reefer in a short time and the creation of certificates with the IDs of the containers, which can be automatically sent to the TOS.
Stacking and Bracing of Pallets
Proper stacking and bracing are critical to maintaining airflow and temperature stability. Perfectly filled Tetris rows are not required here. Airbags, loading beams or straps can keep the load in place. Automated stacking systems can optimise space utilisation and ensure consistent, stable stacking patterns. Temperature mapping can help detect hotspots if problems arise.
Documentation of Procedures and Temperature Controls
The paper trail is compliance's best friend. In addition to transport documents and legal documents such as food safety plans, it is above all the temperature records and inspection reports that provide clarity. The records of temperature and other conditions are like a diary of the journey, ideally in real-time and without gaps over the entire transport route and all stops in ports. Inspections before and during the journey and incident assessments guarantee the impeccable condition of the reefer cargo and equipment or explain how the damage occurred and who is to blame.
Problems with Temperature Protocols
The best monitoring system runs around the clock, without interruption, and in real-time. It also automatically reports when parameters are no longer within the predefined range. Predictive analysis can be used to identify problems before they become critical. In addition, staff must be trained in using clear escalation protocols and, of course, in how to use the monitoring solutions: modern systems have the option of adjusting the settings remotely.
Equipment Failures
Here, too, one should not wait until the machines start to stutter or give up the ghost completely; failures can often be seen as likely based on patterns and avoided through targeted maintenance. When planning the workforce, one should always prepare for specially trained technicians to be available. And it must not be forgotten to keep a well-stocked inventory of critical spare parts.
Faulty Sensors or Incorrect Calibration
Functioning sensors are essential for effective reefer monitoring. But what if these critical components themselves are affected by deviations? This shows the importance of pre-trip inspection, which can reveal inconsistencies in sensor data. Regular calibrations using automated adjustment systems to (re-)establish accuracy are a significant measure. For particularly critical loads, the use of redundant systems is recommended. Sensor replacement should not only be based on failures but also on optimal performance periods. Otherwise, attention should be paid to anomalies and suspicious patterns in the values, as they can indicate sensor problems.
Power Supply Issues
The first measure is the installation of intelligent energy management systems that can detect power fluctuations and outages (read more about reefer management). Modern reefer monitoring systems can also help here, as they indicate a lack of power. Just in case, backup power supply systems such as generators or high-capacity batteries should be available to maintain cooling operations during outages. Another level of security is the generation of one's own energy, for example, through photovoltaic systems and wind turbines within the port facility, in order to be protected against supply problems.
Managing Complex Alarm Systems
In today's work environment, we are bombarded with a large amount of information. "Alarm" suggests to us that an immediate response is necessary. If too many stimuli bombard you continuously, this can lead to what is known as alarm fatigue. Therefore, warnings should be prioritised according to severity and potential impact - based on an essential and urgent matrix. Exact escalation protocols are necessary here; however, these are not set in stone and can be adapted based on new knowledge and experience.
Excessive Transit Times
There are a variety of solutions to avoid delays: route optimisation software that takes traffic, weather and port conditions into account; tracking systems with real-time visibility of the location and condition of cargo; and predictive analytics to mitigate potential delays. The consequences of delays at the port can be addressed with monitoring systems: they report when reefers are left without power for too long and are in danger of no longer being able to maintain the desired temperature and other vital conditions.
How Can Data Optimisation Improve Reefer Operations?
Data is no longer just a byproduct of operations; it is the key to staying ahead. The ability to collect, analyse and derive improvements from data is essential to increasing efficiency.
Let's start with the basics: first, you must figure out what data to collect. As well as the obvious, such as the reefers' conditions and alarms, you should also determine key performance indicators (KPIs) that can be used to determine the current state. They are then essential to assessing your position relative to competitors' benchmarks. And of course, to be able to capture any improvements and their extent.
The measure of all things here is comprehensive real-time data that allows a comprehensive picture. Historical data collected over a more extended period of time offers valuable insights into recurring patterns, such as seasonal peaks or frequent error points. When read and interpreted correctly, they offer a roadmap of how to avoid pitfalls in the future that have repeatedly been encountered in the past.
The main advantage of real-time data is that anomalies are immediately identified, and compliance violations can be prevented. A temperature rise? Noted and corrected before the load suffers. Is the reefer at risk of not being connected to the power supply in time? Seen and dealt with before the conditions in the reefer changed.
With the help of data and advanced analysis tools, container terminal operators can make much more informed decisions. Resource requirements can be forecasted more precisely than ever before. The technologies help us work smarter, not harder—essential in today's working world, especially when every minute counts.
Data optimisation is not just a trend; it is here to stay and evolve - as the backbone of a robust, efficient cooling operation. Companies that embrace it as an opportunity are setting the standard for reliability and performance in the market.
FAQ
What Is a Reefer Pre-Trip Inspection (PTI)?
A PTI is a comprehensive inspection of reefers before they are loaded with cargo. The aim is to ensure that the container is fully functional and clean.
The inspection usually involves checking the refrigerated container's cooling and heating systems to ensure they can reach and maintain the desired temperature. Components such as the compressor, condenser, evaporator and fan are checked for signs of wear or malfunction. The PTI also includes testing sensors and calibrating temperature controllers. Airflow paths are checked to ensure they are clear so there are no temperature fluctuations during transport.
The cleanliness of the container is equally important. Any residue from the previous load can lead to contamination or odour transfer and affect the next load.
A full PTI can take two to four hours, depending on the outside temperature. Some of the latest reefers have self-diagnostic tools that significantly reduce this time without neglecting the quality of the inspection.
Takeaway
Reefers are essential for transporting temperature-sensitive goods, and maintaining the freshness and quality of fresh produce, pharmaceuticals and many other products. However, their operation is complex and requires compliance with manufacturer specifications and international standards.
Non-compliance occurs due to improper cleaning, poor stacking, documentation gaps, temperature control errors, equipment malfunctions and power supply issues. Seasonal peaks exacerbate the challenges and increase the risk of cargo loss, equipment overload and operational bottlenecks (see also: Dangerous cargo).
Effective strategies for ensuring compliance with the diverse regulations include regular maintenance, accurate temperature monitoring and solid documentation. Pre-trip inspections and predictive analytics further increase reliability.
Today, data is no longer something that just accumulates or is hoarded unused but is the key to competing in the market. Optimising it is critical for real-time anomaly detection, accurate resource forecasting and comparability with own and industry benchmarks.
The success of reefer cargo transportation is based on preparation, data-driven flexibility and the use of advanced technology to ensure smooth operations and compliance even in the most demanding conditions.
Delve deeper into one of our core topics: Reefer monitoring
Glossary
FSMA (Food Safety Modernisation Act) - This landmark U.S. law was enacted in 2011 to transform the country's food safety system. It shifted the focus from responding to foodborne illnesses to preventing them. The FDA was given expanded powers to regulate food production, processing, and importation. Key provisions include mandatory preventive controls, increased inspection frequency, and improved traceability requirements.
Temperature Mapping - The process of temperature mapping is used to evaluate and document consistent temperature levels in controlled environments. Sensors are placed at various locations to monitor the temperature over a period of time and to identify hot spots, cold spots or uneven airflows and make adjustments.
Sources:
(1) https://www.fao.org/nutrition/capacity-development/food-loss-and-waste/en/
(2) https://food.ec.europa.eu/food-safety/food-waste_en
(3) Global Cold Chain Alliance: Refrigerated Transportation Best Practices Guide https://www.gcca.org/legacy-system/Refrigerated%20Transportation%20Best%20Practices%20Guide%20WEB.pdf
