How does automated reefer monitoring work?

It’s a common question, even for those well-versed in reefer terminal activities. Yet, it’s easy to understand the confusion. Compared to dry containers, refrigerated containers require attention. They need electricity to maintain temperature and be looked after closely to ensure the set temperature remains constant. The terminal operator stays on top of it all by collecting information. How this is done can vary.

For this month's issue of The Reefer Monitor, let's take a closer look at how reefer monitoring works, especially when compared to manual data collection.

The Reefer Monitor | Issue #8 - July 2024

Let’s first lay the foundation for reefer monitoring.

The traditional method, which involves a manual and burdensome process of gathering information from all the refrigerated containers in the yard, is highly inefficient. This includes physically visiting each reefer, reading the information on the display panel, and then recording it for later data entry into the terminal’s operating system. If the reefers are in a rack, it's manageable. The technician can simply walk the stairs and catwalks, continuing to gather data along the way. However, stacked reefers present a more significant challenge and risk, requiring scissor lifts or booms to access data from reefers atop the second level or higher.

As you can imagine, this process can be very time-consuming. And if the terminal has hundreds of reefers, long delays between readings can be expected. Intervals of 6, 12, or even 18 hours are not uncommon. During that time, terminal management is blind to changes occurring at each reefer, exposing perishable cargo to risk should an undetected event happen in the interim. Relief from this process is possible with the introduction of automation, offering a promising solution to the challenges of manual reefer monitoring.

Now, let's dive into the solution to these challenges - automation.

Automated reefer monitoring is a game-changer, offering a host of benefits. It provides real-time data whenever a change occurs that might affect cargo quality, ensuring continuous monitoring without any delays. This constant vigilance offers a sense of security and confidence in the terminal's operations, as it reassures the operator of cargo safety 24/7. The benefits of automation are clear, offering a significant improvement over the manual process and revolutionizing reefer terminal activities. The continuous monitoring aspect of automation can instill a sense of security and confidence in all cargo stakeholders, knowing that their cargo is being looked after around the clock.

To achieve this, monitoring devices are positioned at every reefer point. They can be hard-mounted to reefer rack structures or attached directly to individual reefers. These devices are designed to tap into the inherent data available within each reefer control panel. They do this via a cable connection between the monitoring device and the reefer’s data port.

When a reefer arrives at the terminal and is placed into position, either in a rack or stacked location, the technician plugs the reefer into the on-site electrical source and then connects the monitoring device’s cable to the reefer’s data port. From that moment, terminal management starts receiving detailed information about the reefer.

Depending on the terminal infrastructure, this data is sent via wireless or ethernet to a local or cloud-based software system. From here, terminal personnel can view the entire reefer yard at a glance and know precisely the status of every connected refrigerated container.

Information like container ID, set point data, current temperature and humidity, CA values, USDA logs, and more is instantly available. Even recovered trip records highlight excursions from temperature set points long before the reefer landed on the terminal. This is essential information for the terminal manager to protect themselves in case of future loss claims should the cargo reach its destination damaged.

For example, what if the booking temperature does not match the actual temperature in the reefer? Ensuring your terminal is aware of this and can take corrective measures quickly is essential to protecting the cargo. When reefer monitoring is connected to a terminal operating system (TOS), automation compares the required set point against the current data from the reefer. An alarm will notify site management of an error if this information does not match. The monitoring system provides a two-way communication link between the software user interface and each reefer controller, allowing managers to update set points remotely, without delay, and without physically visiting the reefer location.

Accuracy is also paramount. With automation, all the collected data is digitally retrieved directly from the reefer controller, so there is no worry about inadvertent mistakes in recorded data.

How does eliminating the manual process affect the technician, whose job is to collect the data? Is this person now out of work? No, on the contrary. Automation increases the efficiency of the entire operation. Like most businesses, many terminals are experiencing staffing challenges. When their limited team of technicians is out collecting data, they may need help to address other more pressing needs, like when a mechanical failure causes a reefer to shut down. This is a critical situation that requires immediate attention. If technicians are pulled from one job to another, something will surely be missed. The reefer alarm will have to wait, or the manual inspections will be paused. Each offers potential risk to the cargo.

Through automated reefer monitoring, staff technicians can respond more quickly to all terminal work orders and alerts, reacting only to exceptions. This improves terminal efficiency and increases cargo quality, helping the management team make better decisions for improved performance.

Other benefits of reefer monitoring systems

• Optimizes reefer data management process
• Coordinates reefer data with TOS software, including location verification
• Efficiently utilizes terminal assets for better outcomes
• Maximizes results with real-time alarm notifications
• Increases personnel and cargo safety while reducing insurance claims

Automated reefer monitoring adds value to the quality of care the terminal provides its customers – a driver of future business opportunities and growth.

Increase efficiency and grow your operation with RTE.

RTE recognizes the difficulties a lack of data can pose to reefer terminal operations. As your reefer terminal expands, these difficulties become more apparent, emphasizing the importance of gaining control over the data collection process. Whether you are establishing a new reefer terminal, upgrading an existing facility, or adapting to changes in reefer throughput, RTE is the reliable partner for your success.

With a proven track record of innovation spanning four decades, RTE can create a tailored automated reefer monitoring solution that precisely meets the needs of any terminal. Get in touch with us today to find out more about our systems.