Cold Comfort: Rethinking Refrigeration For The Modern Fleet
The next evolution of cold chain logistics is quieter, cleaner, and more data-driven.
For fleet managers running refrigerated vans, keeping cargo cold has never been as simple as flipping on a cooling unit and hitting the road. Today’s cold chain operations sit at the intersection of regulatory scrutiny, sustainability goals, rising fuel costs, and increasingly unpredictable weather.
“Companies operating refrigerated cold chain fleets face several key challenges that can disrupt the distribution process and risk product integrity,” says Kyle Hammontree, Business Segment Manager at Geotab. “These challenges include regulatory compliance, weather conditions, lack of temperature visibility, and equipment failure.”
Each of these challenges on its own can strain operations. Together, they’re pushing fleets to rethink how refrigerated vans are powered, and whether relying on the vehicle’s engine still makes sense.
Compliance issues
Regulatory compliance is often the most immediate pressure point. Food and pharmaceutical fleets are required to prove that products stayed within strict temperature ranges throughout their journey, with detailed documentation to back it up. Failing to do so can mean fines, or even full-scale product recalls.
“There are many industry regulations and guidelines fleets must adhere to,” Hammontree explains, citing Good Distribution Practices (GDP) for pharmaceuticals, HACCP and Safe Food for Canadians Regulations for food safety, the U.S. Food Safety Modernization Act (FSMA), and oversight from agencies like the FDA and USDA.
The challenge isn’t just meeting these standards—it’s proving compliance. That’s why keeping accurate records is critical. “Use technology to automatically save temperature data and other details,” Hammontree advises. “This creates historical records that are ready for audits, and needed to follow rules like FSMA.”
Environmental concerns
Then there’s the environment outside the cargo box. Extreme weather events—heat waves, cold snaps, sudden storms—can overwhelm refrigeration systems and compromise temperature stability. As Hammontree notes, sudden temperature changes can spoil the product if fleets can’t react fast enough.
Traditionally, fleets have relied on engine-powered refrigeration units. Vans idle to keep goods cold while drivers unload, wait at docks, or navigate congested urban routes. That idling burns fuel, increases CO₂ emissions, and accelerates wear and tear on engines.
Over time, the costs add up: higher maintenance bills, more frequent breakdowns, and increased downtime. Equipment failure, especially refrigeration unit failure, is one of the most expensive risks fleets face. Even a short interruption can result in lost product and damaged customer trust.
A shift away from engine-driven cooling
To reduce these risks, many fleets are exploring alternatives that keep cargo cold without running the engine. According to Hammontree, the goal is simple: “Stop relying on the van’s engine for cooling.”
Several technologies are gaining traction:
Liquid nitrogen (cryogenic cooling) uses the evaporation of liquid nitrogen to rapidly chill the cargo area. Hammontree says this process is nearly silent and produces no CO₂ during cooling.
Solar power involves roof-mounted panels that charge auxiliary batteries, which then power the refrigeration unit independently of the engine.
Battery-electric power (E-TRUs) relies on large lithium-ion batteries that can be charged via plug-in power and regenerative braking. These systems pair naturally with electric vans, which are increasingly common in last-mile delivery.
Each option reduces engine load, cuts emissions, and lowers the risk of mechanical failure tied to traditional systems, but none is a one-size-fits-all solution.
Weighing costs, reliability and reality
So which alternative makes the most sense? Hammontree says it depends heavily on how and where a fleet operates.
“The most realistic solution depends on the fleet’s vocation and the type of routes they drive—last-mile versus long-haul,” he explains. “Battery/electric (E-TRUs) are being adopted the fastest because electric vehicles are becoming more popular for last-mile delivery vehicles for food and beverage distribution, as well as pharmaceutical distribution.”
Battery-powered E-TRUs stand out for reliability and long-term savings. They produce no tailpipe emissions, reduce fuel costs, and integrate well with electric vehicles. However, Hammontree explains that they come with a high upfront price tag, add significant weight, and require charging infrastructure.
Solar power offers “free” energy from the sun, reduces stress on the engine, and helps maintain battery health. The downside? It’s very weather-dependant, rarely provides enough power for heavy cooling on its own, and requires maintenance if panels are damaged or dirty.
Liquid nitrogen systems are great for night deliveries since they’re almost silent, cool rapidly, and have few moving parts to break, Hammontree explains. However, they require a specialized refueling infrastructure, face fluctuating fuel costs, and come with safety considerations related to gas handling.
Data-first approach
For fleet professionals considering alternatives, Hammontree emphasizes a strategic, data-driven approach.
“The most successful strategies centre on a data-first approach,” he says, and he recommends using telematics to measure current performance. “Use telematics to measure exactly how much fuel is being wasted today when vans sit idle just to keep the goods cold,” he says. “If you don't measure it, you can't improve it.”
Piloting new technology is another critical step. Rather than overhauling an entire fleet, Hammontree recommends testing a small number of vehicles on specific routes. This allows fleet managers to evaluate real-world factors like frequent door openings, stop-and-go traffic, and driver behaviour.
Total Cost of Ownership (TCO) should guide decision-making. While battery or cryogenic systems may cost more upfront, savings from reduced fuel use, fewer engine repairs, and longer vehicle life can outweigh initial expenses over five to seven years.
Visibility: a top priority
No matter which cooling technology a fleet chooses, visibility remains non-negotiable. Smart sensors that continuously monitor temperature and humidity—and trigger alerts when something goes wrong—are key to protecting cargo.
“Make sure your cooling source works with your tracking system,” Hammontree advises. Immediate warnings can save a shipment if a battery fails or a nitrogen tank runs low, he adds.
Route planning also plays a role. Avoiding traffic congestion and severe weather not only saves time and fuel, but also reduces stress on refrigeration systems. Additionally, automated record-keeping ensures fleets are always audit-ready, with historical data available at the click of a button.
Keeping cool in a changing industry
Refrigerated fleets are under more pressure than ever, but they’re also better equipped than ever to respond. Cleaner cooling technologies, paired with telematics and data-driven planning, offer a way to reduce costs, meet compliance demands, and lower environmental impact—all while keeping products safe.
