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Hybrid Trailer Refrigeration Units

The analysis and conclusions contained in this case study are those of the authors alone and do not necessarily represent the point of view of the Government of Canada.

Organization
Paradise Island Foods Inc.

Major Findings
Hybrid trailer refrigeration units reduced fuel consumption and greenhouse gas (GHG) emissions by 61% and provided a payback period of 15 months. Onboard computers in trucks reduced fuel consumption and GHG emissions by 13% and provided a payback period of 18 months. Trailer refrigeration units proved reliable and quiet while onboard computers systems were reliable and readily accepted by drivers.

Project Timeline
March 2008 to February 2009

Please note that some figures such as cost savings on fuel are based on data from the period that this project took place.

Introduction

Paradise Island Foods Inc. is a Nanaimo, British Columbia, company that produces cheese and dairy products. It relies on its own fleet of four tractors and seven refrigerated trailers to deliver products throughout Vancouver Island and the lower mainland of British Columbia.

In 2005, Paradise Island Foods implemented a corporate speed limit of 90 km/h, an idle limit of three minutes and progressive shifting limits to avoid over-revving. In addition, the company enrolled all drivers in Natural Resources Canada’s FleetSmart program. Drivers participated and took advantage of a company incentive program which shared half the fuel savings with the drivers.

In 2007, Paradise Island Foods Inc. upgraded its trucking fleet by purchasing four Kenworth T660 day cab tractors. These trucks were designed to provide maximum fuel economy and overcome the fuel consumption challenges of low-emission engines.

Project Description

In 2008, with funding from Transport Canada’s Freight Technology Demonstration Fund, Paradise Island Foods Inc. began a demonstration project to field test the ability of hybrid trailer refrigeration units and truck onboard computer systems to reduce fuel consumption and greenhouse gas (GHG) and criteria air contaminant (CAC) emissions.

The refrigeration units on six trailers were replaced with hybrid refrigeration units and electrical plug-in equipment was installed at the company loading bays. The Carrier Vector Hybrid refrigeration units run on electricity when plugged in, and when on the road, a diesel generator creates the electricity to provide cooling and heating. This type of refrigerating unit has fewer moving parts and uses half the refrigerant of traditional units. The units can provide multiple temperatures to compartments in the trailers established by moveable bulkheads. This technology had particular potential for Paradise Island Foods due to favourable electric power rates in British Columbia and because the company makes mostly same-day deliveries, allowing the trailers to return to electrical plug-in power overnight.

Onboard Tractor Computer Systems were installed in all four tractors and drivers were trained to use them. The XataNet computers provide electronic log capability, GPS location, satellite communications, idle time tracking and performance recording. This technology had the potential to help drivers with speed management, optimum shifting, optimum route selection, and idle reduction.

Project Goals and Objectives

The objective of this demonstration project was to reduce fuel consumption and greenhouse gas (GHG) emissions through the installation and monitoring of two technologies.

The project’s goal was to reduce the refrigeration unit’s diesel fuel consumption by 36% and to reduce the truck fuel consumption by 21%.

Project Methodology

The data collection for the demonstration project occurred between March 2008 and February 2009. For both technologies, fuel reductions were converted to GHG emission reductions based on Environment Canada factors.

Hybrid Refrigeration Units

Baseline data was established for a standard diesel refrigeration unit and for a hybrid refrigeration unit running solely on generation mode. The data collected to measure fuel consumption reductions of the hybrid refrigeration unit were: hours of operation, temperature settings, and fuel consumption. The refrigeration unit hours were recorded by drivers on a daily basis. The refrigeration unit tanks were refilled daily and provided a daily summary of fuel usage. The hybrid refrigeration units and tractors were used exclusively on Vancouver Island and the lower mainland during the test period.

Both single temperature and multi-temperature hybrid units were installed and tested. Both have the same controls as traditional diesel refrigeration units. Some training was required to make electrical connection and disconnection safe.

Tractor Onboard Computers

The four new Kenworth trucks were operated ungoverned (without onboard computers or electronic control modules) for two months to collect baseline data consisting of average distance travelled per period, average transported weight (tonnes) and fuel consumption (liters).

After the onboard computers were installed, the trucks were operated in similar weather conditions (considering both seasons winter and summer seasons) and similar routes (highway vs. city) to compare fuel consumption and emissions. Fuel reductions were converted to GHG emission reductions based on Environment Canada factors.

Results

The hybrid refrigeration units surpassed the objectives for fuel and greenhouse gas emission reductions (Table 1). The on-board computers did not meet the target objectives, but did provide significant reductions in fuel consumption and associated reductions in greenhouse gas emissions.

   Table 1 Project Objectives and Results

Technology	Measure	Objective	Result1
Hybrid Refrigeration Units	Diesel fuel reduction	36%	61%
	GHG emission reductions	36%	85 tons (6 trailers over 6 months)2
	CAC emission reduction	36%	588 kg (6 trailers over 6 months)2
	Maintenance reduction	20%	16%
Tractor Onboard Computers	Fuel reduction	21%	13%
	GHG emission reductions	21%	6.8 tons (4 tractors over 6 months)2
	CAC emission reduction	21%	46.6 kg (4 tractors over 6 months)2
	Maintenance reduction	15%	15% (est.)

1. Results are based on electricity and diesel fuel costs for 2008.
2. Due to the close correlation between fuel consumption and greenhouse gas emissions, it was
concluded that the hybrid refrigeration units reduced greenhouse gas emissions by about 61% and the onboard computers resulted in a reduction of about 13%.

Both new technologies were quickly accepted and embraced by drivers and warehouse staff. This was attributed to sharing goals and performance results with the team during planning and implementation.

Hybrid Refrigeration Units

Based on Paradise Island Foods’ needs, the hybrid refrigeration units resulted in a 61% reduction in diesel fuel consumption. All seven trailers have now been converted to hybrid refrigeration units. The capital cost premium for acquiring one hybrid refrigeration unit is about $4,500 compared to a conventional refrigeration unit. Taking into account the additional cost of electricity, the monthly net savings in fuel usage and reduced maintenance, each hybrid unit results in net savings of about $300 per month. This means, for the diesel fuel and electricity rates for Vancouver Island, the payback period for a hybrid refrigeration unit is 15 months.

Drivers were impressed with the greater temperature performance and reduced noise. The hybrid refrigeration units provided better performance than traditional fuel-powered units in terms of heating, cooling and defrosting. The units are substantially quieter when running on plug-in power. Noise complaints from neighboring properties have ceased.

Initial safety issues related to the use of plug-in electricity for the hybrid trailers were addressed by implementing a training program and developing a number of safety features including: key lock activation, warning signs, beacon lights, plug weather covers and fail safe special plugs.

Paradise Island Foods concludes that hybrid refrigeration units are well-suited for shipping operations where trailers can be connected to electrical power while loading, unloading or awaiting dispatch. This would include regional fleets, where vehicles are typically away from a distribution centre for up to two days. Long haul highway fleets would likely not see substantial benefits from this technology until facilities for connection to electrical power while they are away from their home base are more widely available.

Tractor Onboard Computers

The onboard computers reduced fuel consumption by 13%, and emissions by a comparable amount. Current fleet fuel economy is 2.5 kilometers per liter, while current fleet idle time is consistent at 1.6%. The onboard computers have performed well. In addition to increasing tractor fuel efficiency, they improved regulatory compliance and maintenance accuracy. The onboard computer operation was very easy for drivers to learn – approximately one hour of training time was required per driver. More training and adjustment time was required for the dispatch team.

The onboard computer systems cost approximately $4,500 per truck. Monthly communication and software upgrade costs of approximately $75 per truck and the computers have realized a monthly fuel saving of $333 per truck, resulting in a payback period of 18 months.

In addition to fuel and emissions reduction, the onboard computers have allowed Paradise Island Foods to run full electronic logs for drivers, better driver hour tracking, direct communication via text messaging, location tracking, and reduction of out-of-route kilometers.

Conclusions

This project demonstrated two technologies that Paradise Island Foods Inc. found to be reliable and cost-effective for reducing fuel consumption and GHG emissions. Both technologies are commercially available.

The hybrid refrigeration units reduced diesel fuel consumption by 61% and provided other operational advantages (for examples, better temperature regulation, faster defrosting, and quieter overnight operation). Hybrid trailer refrigeration units seem to be best-suited for regional carriers that can use electrical power while trailers are located at the home base.

The onboard computer systems will provide benefits for all types of trucking companies. They helped drivers and managers reduce tractor fuel consumption and associated GHG emissions by 13% and provided a number of operational advantages (for example, better driver hour tracking, direct communication via text messaging, location tracking, and reduction of out-of-route kilometers).

Additional Information

• Paradise Island Foods Inc.
• Carrier Transicold (Vector Hybrid)
• XATA  

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Date modified:

2012-03-08

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