Refrigerated transport ready for the future

The global push towards decarbonisation in the transport and logistics sector has sparked a wave of innovation in refrigerated container and trailer technologies including hybrid and fully electric systems, as well as advanced energy recovery solutions.

Companies worldwide are introducing groundbreaking designs aimed at reducing emissions, improving efficiency, and meeting evolving environmental standards. These advancements address the regulatory challenges and pave the way for more sustainable cold chain logistics.

Maersk’s Multi-refrigerant Reefer

In response to the global HFC phase-down under the Kigali Amendment to the Montreal Protocol and an evolving regulatory landscape, Maersk Container Industry (MCI) has introduced the ‘Star Cool 1.1’ reefer container designed for adaptability and sustainability.

Maersk head of reefer technology Paul Clarke describes the new container as a “significant innovation”.

“Its ability to operate efficiently across multiple refrigerant options not only highlights its flexibility but also its readiness to meet both current and future safety and environmental standards,” he said. 

According to Maersk, this dual-pronged approach enables the Star Cool 1.1 to cater to diverse operational needs while remaining committed to environmental responsibility.

By employing R1234yf, the Star Cool 1.1 offers a significantly lower direct greenhouse gas footprint compared to R134a and R513A systems, contributing to a reduced carbon footprint across the container’s lifetime. 

Beyond its environmental potential, the Star Cool 1.1 offers significant operational advantages through advancements in compressor technology and design optimisation, achieving a claimed eight per cent reduction in energy consumption compared to previous models, reducing operating costs and carbon footprint.

The reefer also features a built-in energy meter that wirelessly transmits data through MCI’s Sekstant reefer monitoring solution so operators can track energy savings and convert this information into carbon footprint data for specific voyages.

Sunswap Secures £17.3m to Expand on Eco Reefers

Sunswap, a UK cleantech company tackling cold chain logistics emissions, has secured £17.3 million to rapidly expand its zero-emission refrigeration technology across the UK and Europe.

The investment, led by BGF (Business Growth Fund), comes from a group of investors including Shell Ventures, Move Energy, and existing backers Barclays and Clean Growth Fund. 

Sunswap can now expand its production capacity to meet increasing demand for its sustainable solutions. The start-up will also invest in building a nationwide service network to support a growing customer base. 

Sunswap’s ‘Endurance’ system, seen as a game-changer for the trucking industry, replaces traditional diesel-powered refrigeration units with a completely electric solution that has been proven to significantly improve efficiency through rigorous trials with major companies like supermarket giant Tesco and German dairy product brand Muller.

The Endurance reefer combines solar panels mounted on the trailer roof with cutting-edge rapid charging batteries, generating clean energy to power the refrigeration unit. 

A cloud-based telematics system means operators can remotely monitor and control the units, helping optimise operations and reducing costs.

Sunswap chief executive Michael Lowe said this latest funding round will also help the company to “support further customer trials, and invest in the development of our zero-emission technology”.

“Together, we will work towards a cleaner, greener future for cold chain logistics, helping businesses meet their sustainability targets.”

Sunswap’s commitment to sustainability extends to membership of the ‘Move to -15°C’ coalition, which aims to raise frozen food temperature standards from -18°C to -15°C, which would significantly reduce greenhouse gas emissions and lower supply chain costs.

In fact, Sunswap’s own research shows that many operators currently use temperatures as low as -22°C, and raising them to -15°C could save a fleet of 500 trailers the equivalent of A$4.9 million in diesel costs as well as reduce CO2 emissions by 46 per cent – equivalent to removing 1203 cars from the road for a year. 

Carrier Transicold’s ‘Hydro-Electric’ Reefers

Carrier Transicold’s new power modules, Eco-Drive and Eco-Drive T are compatible with a wide range of truck types and utilise a truck’s engine to generate electricity for powering refrigeration units, helping fleets reduce emissions and operating costs.

The Eco-Drive system, mounted on the prime mover’s chassis is a hydro-pump connected to the truck’s engine power take-off which drives a generator, providing electricity to operate refrigeration units like the Vector 1550 E City (all-electric) or the Vector HE 19 MT without relying on their own diesel engines.

Carrier’s ‘X-Flow’ technology is said to ensure a consistent power supply, independent of the truck’s engine speed, guaranteeing 100 per cent refrigeration capacity even when the vehicle is idling.

The Eco-Drive modules are compatible with all Euro VI technology across diesel, CNG, LNG, and ethanol fuel types. 

In addition to reduced maintenance costs, Carrier says they lower fuel consumption by 2-4 litres per hour compared to traditional systems relying solely on the refrigeration unit’s engine, which cuts CO2, NOx and particulate emissions – contributing to the company’s goal of reducing customer carbon footprints by more than one gigaton by 2030. 

Carrier Transicold Australia product and aftermarket solutions director Kelly Geddes said the new Eco-Drive T variant fits behind the cabin of the prime mover, “making it ideal for vehicles where there is no space underneath the chassis”.

British cold chain operator Freshlinc, a long-standing Carrier Transicold customer, has recently taken delivery of its first prime movers equipped with Eco-Drive to run its Vector 1550 equipped reefers, a combination ideal for transporting frozen or chilled foods in urban areas due to quiet operation (under 60 dB(A)), quick pull-down speeds and precise temperature control.

Carrier Transicold UK Key Account Manager Martin Parker said the company was “delighted that Freshlinc sees Carrier’s cutting-edge technology as the ideal solution for reducing its fleet’s carbon footprint, and these units will deliver critical fuel and emissions savings”.

Spain embraces Thermo King’s self-charging reefer

Spanish logistics group Carreras has been operating a refrigerated semi-trailer equipped with Thermo King’s innovative self-charging electric refrigeration system since January this year and has already run the reefer for more than 55,000km entirely on electric power, thanks to the system’s unique design.

“This project and collaboration with Thermo King and its dealer Frigicoll mark a significant stride for Carreras in embracing sustainable logistics,” said Carreras director of projects, consulting, sustainability, and innovation Héctor Benito Serón.

“Through the integration of the new technology, we managed to deliver tangible, efficient, and direct enhancements to our operations.”

The system incorporates Thermo King’s Advancer hybrid refrigeration unit, powered by the company’s AxlePower dynamic energy recovery system, which includes the ENERG-e battery pack to harness energy generated during braking and coasting, storing it within the battery pack to power the refrigeration unit.

“The ability to harness and generate energy directly from the trailer’s movement makes this technology a sustainable solution for diverse transportation needs,” explained Thermo King area sales manager Francisco Cambra Soriano.

The system’s intelligent control unit dynamically assesses road conditions and driving behaviour to optimise both kinetic and thermal energy recovery from the trailer’s e-axle.

A sophisticated power management system automatically selects the optimal operating mode without driver input.

The modes comprise energy recuperation, passive operation (using existing battery charge), and active charging (to maximise battery life and minimise energy consumption), with real-time battery data available to fleet managers for proactive monitoring and to alleviate range anxiety.

By eliminating the need for external charging, this technology significantly increases uptime, reduces operating costs, and minimises carbon emissions. Its silent, battery-powered operation when running on battery power makes it suitable for deliveries in urban areas, including Ultra-low Emission Zones (ULEZs) and low-noise zones. 

Carreras also operates its fleet on biofuel, which, according to the company, lowers total emissions by 90 per cent.

“We are proud of our unwavering commitment to decarbonisation and process improvement, ensuring the highest quality services for our customers,” said Serón. 

“This project brings us another step closer to our ultimate goal of a 50 per cent reduction in carbon footprint.”

The innovative AxlePower system is a collaborative effort between Thermo King and BPW (Bergische Achsen KG), a leader in running gears and mobility services for transport. 

AxlePower combines BPW’s ePower axle with a Thermo King ENERG-e battery pack and smart power management technology, creating a fully integrated system that is independent of the prime mover and, unlike other axle generators, disengages on inclines, preventing wasted energy to further reduce fuel consumption.

“At a time when consumer demands increasingly prioritise sustainability, low or zero emission and resource-saving supply chains are becoming an important selling point,” said Soriano.

“Carreras utilising the self-charging AxlePower solution will secure long-term competitive advantages and establish themselves as frontrunners in sustainable practices.” 

Can Electrified Trailers Revolutionise Green Trucking?

The Heavy Vehicle Industry Association (HVIA) is working to bring powered trailers – trailers that have their own engines or batteries – to Australian roads.

HVIA recently met with government officials, focusing on trailers with “motive power axles,” which means the trailer can help with the driving using its own power source.

This meeting resulted in two key strategies: 

Regulatory Alignment: To facilitate the seamless adoption of powered trailers within the Australian transportation landscape.

Real-world Validation: To develop a framework for on-road trials of powered trailers in Australian trucking operations.

In September these plans were presented to the Vehicle Standards Consultative Forum (VSCF), a body responsible for advising the Australian government on vehicle standards.

HVIA is now sharing details about the meeting and proposed strategies with the HVIA Powered Trailer Working Group and, once endorsed, with the broader membership.

Efforts to integrate powered trailers into Australia’s trucking landscape are fuelled by the revolutionary potential of technologies like ZF’s TrailTrax, which harnesses electric axles and a robust mains-rechargeable battery system that can also capture energy through regenerative braking to power electric equipment such as refrigeration units.

The result is a significant leap forward in efficiency, transforming diesel trucks into hybrids, cutting fuel consumption by 16 per cent, and extending the range of electric or even fuel cell trucks.

“Electrification for trailers is an innovative solution to decarbonise road freight transport in the very near future,” explained Dr. Bernd Meurer, responsible for the electric trailer program at ZF.

“Instead of solely being pulled by the truck, the new approach provides additional traction while generating fuel savings, reducing CO2 emissions, and improving sustainability.”