In January 2023, the Australian Bureau of Statistics (ABS) revealed that Australia’s Consumer Price Index (CPI) had risen 7.8% for the year to December, representing the highest level since 1990. It is a challenging economic climate for all Australians, and the difficulties faced by transport companies is perhaps best demonstrated by the February 27 announcement that Scott’s Refrigerated Logistics had entered voluntary administration.

Prime Mover Magazine notes that soaring diesel prices, global knock-on effects of the Ukraine war, higher AdBlue costs and the impact of the previous government’s six-month fuel tax cut are all hitting transport operators. With so many external factors impacting costs, it has never been more important for cold chain operators to ensure their equipment is as efficient and cost-effective as possible. Reducing the tare weight of intermodal freight containers presents a genuine opportunity to cut OPEX significantly, with Railbox’s lightweight refrigerated containers present as a potential solution.

Lightweight Intermodal Refrigerated Containers

The key to achieving a good lightweight intermodal container design is to carefully evaluate where it is possible to refine structural members or substitute materials to reduce tare weight without compromising strength and durability in critical regions. Railbox continues to develop its lightweight refrigerated product line, striking the optimum balance through the application of high-fidelity finite element analysis and load testing.

Railbox lightweight refrigerated containers retain high-strength steel intermediate and end frames to ensure that there is no comprise to the lifting, stacking, and racking capacity of the container and a strengthened sub-floor at the door end, as this is the zone subjected to repetitive loading. Significant weight reduction is achieved through the use of aluminium external wall and roof sheeting, side rails, and floor cross-members, with the selected material grades providing comparable yield strength and corrosion resistance to stainless steel.

Internally, fibre-reinforced polymer (FRP) is utilised for wall and door linings which offers further weight reduction. FPR has found favour in the transport sector for the following reasons:

• Excellent chemical and corrosion resistance
• Superior impact resistance
• Approximately 80% lighter than stainless steel, reducing the tare weight of the container
• Food-grade product, easily cleaned
• Repairable if damaged

Cost Analysis Example

Rail transport cost: 5¢/ntk (net tonne km) #

Average trip distance: 1900km

Estimated loading cycles: 100/year

Operational life: 12 years

For the assumed parameters above, a container tare weight reduction of 800kg equates to an Operational Expenditure (OPEX) saving of more than $80,000 over the life of the asset.

# Rail freight costs published by L.E.K. Consulting Australia for the Department of Infrastructure, Transport, Regional Development and Communications in 2021.

Key Considerations

Before committing to build a fleet of refrigerated containers:

• Investigate your anticipated freight profile. Do you expect to be limited by the rated payload or the volumetric capacity of the container?
• Consider how are you charged for rail services, and calculate the potential cost reductions you would expect to achieve for a unit tonne of tare weight reduction.
• Remember that lessors may be more reluctant to commit to a lease for a lightweight design, so consider whether a purchase or long-term lease suits your business model better.
• Consider how frequently you expect the containers in your fleet to be loaded and unloaded.
• Check which types of material handling equipment you will be using to load and unload the containers. Do your forklifts, stackers and pallet trucks have pneumatic tyres or polyurethane wheels?
• Consider whether you expect to maintain control of the equipment throughout its operating life or whether you plan to lease / sub-lease the equipment to others.
• If you do plan to lease / sub-lease the containers, ensure you consider how you will ensure that the containers are handled, maintained and cleaned appropriately to avoid accelerated degradation and depreciation.

For more information, contact your local Railbox representative to discuss an appropriate solution for your operations. Your business – on track.