Solving Challenges in Refrigerated Air Freight

The modern cold chain is more advanced than ever thanks to real-time GSM (Global System for Mobile Communications) and temperature data, but there’s a significant weak spot many companies still struggle to address: refrigerated air freight.

Air transportation is both expensive and carbon-intensive, leading the vast majority of produce to be transported by sea, road, or rail. However, some highly perishable fruits and vegetables (such as berries and asparagus), must be moved quickly to reach consumers at peak freshness. That leaves air freight as the most viable option, especially for international supply chains.

Transporting temperature-sensitive produce via air introduces a unique set of cold chain challenges that can lead to costly losses. Fortunately, there are proven strategies that distributors and supply chain professionals can employ to minimize temperature fluctuations and safeguard product quality.

Challenges in Cold Chain Air Freight

Many airports and aircraft lack sufficient temperature controls, exposing delicate cargo to dramatic temperature fluctuations that compromise quality. Given the high costs associated with air freight, these losses can severely impact your company's bottom line.

On the Ground

The journey from truck to plane is the most vulnerable link in the air freight cold chain. Airport security screenings, customs checks, and tarmac loading often take place in unrefrigerated environments.

The biggest risk comes at the loading phase, particularly in extreme climates. Unexpected delays due to weather conditions, air traffic control issues or mechanical problems can significantly prolong exposure. Too much heat causes produce to wilt, while excessive cold can lead to the formation of damaging ice crystals. Insulated thermal covers offer some protection, but they aren't always enough.

In the Air

Aircraft cargo holds often have limited temperature control capabilities compared to refrigerated trucks or warehouses. Fluctuations in air pressure and altitude during flight can affect the internal temperature of the cargo hold, particularly during ascent and descent. Exposure to multiple dramatic temperature shifts in a short period of time can degrade produce quality.

The Biggest Challenge in Refrigerated Air Freight

Unfortunately, the responsibility for maintaining optimal temperatures often falls on individual companies rather than the airlines.

International journeys between countries with different customs procedures and shipping capabilities add another layer of complexity to maintaining your cold chain. This is especially true when there are significant differences between on-the-ground and in-flight temperatures.

Another obstacle is the need to maintain high humidity during transportation. Air is dry at high altitudes, and cargo planes lack the ability to regulate humidity. Fluctuations in both temperature and humidity can severely impact shelf life and expiration dates.

For example, berries and other fruits begin to shrivel when humidity levels dip below 95% for extended periods. Similarly, produce with high water content, like blueberries, are susceptible to ice damage when thawed, resulting in an undesirable mushy texture.

A New Approach to Cold Chain Air Freight

Solving these air freight temperature control challenges is complicated. Distributors often lack visibility into procedures and processes in this link of the cold chain. This makes it difficult to pinpoint specific actions they can take to improve quality control.

Sensitech can provide the monitoring equipment and analytics support you need to gather actionable insights. Our GSM-enabled monitors transmit real-time location and temperature data from your shipments. By analyzing this data, our professional services team can help you identify the root causes of temperature deviations and recommend solutions based on your specific needs.

Case Study: Produce Wholesaler and Blueberry Air Freight

A Spanish fruit and vegetable wholesaler faced transportation challenges in its blueberry supply chain. Product quality was suffering due to persistent temperature fluctuations in their shipments from Morocco.

Sensitech developed a strategy to help the company pinpoint the cause of these excursions and identify a solution. Using real-time tracking devices, we gathered data on the movement of blueberry shipments through the air freight cold chain. Analysis revealed excessive ambient temperatures inside the blueberry containers during transit.

The company used these insights to implement corrective measures, including enhanced pallet insulation and ice packs to protect the blueberries from prolonged heat exposure. The adjustments proved effective, as pallets maintained their desired temperature range more consistently during ground and air transport. This resulted in fewer temperature-related claims from customers and a significant decrease in product loss.

Cold Chain Air Freight Solutions

Sensitech’s temperature monitors empowered the company to make strategic, data-driven process improvements to prevent significant temperature excursions going forward. These solutions included:

• Real-time Temperature Monitoring: Internal and external temperature monitoring devices measure ambient and internal temperatures to assess the efficacy of temperature control equipment.
• Temperature Control Equipment: While not directly provided by Sensitech, solutions like thermal blankets and ice gels on the tarmac can help control temperatures during critical stages.
• Interoffice Communication: Sensitech’s professional services teams can assist in training and educating airport staff, fostering better communication and collaboration in temperature-sensitive cargo handling.

Final Thoughts

Maintaining the cold chain in air freight demands constant attention and strategic action. With the help of Sensitech's monitoring devices and professional consulting services, you can precisely identify breaks in the cold chain and introduce corrective actions.

Ensure your temperature-sensitive products reach their destination in optimal condition. Get in touch to learn how Sensitech can help you overcome challenges in your air freight cold chain.

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