Case 1: Refrigerant Leak due to Incomplete Inspection

A Latin American fruit exporter suffered a breakdown during a transatlantic voyage in a Carrier reefer. The internal temperature rose from -1°C to +10°C, rendering a cargo valued at $150,000 unusable. The cause: a refrigerant leak in the compressor caused by a worn-out gasket that was not detected during the PTI (Pre-Trip Inspection).

Common Error:
Performing superficial inspections that verify basic parameters but omit a meticulous visual check of the refrigeration circuit.

Lessons Learned:
Vibrations during sailing can aggravate micro-fissures that go unnoticed in port.

Preventive Tips:

• Conduct full PTIs at least 48 hours before loading.
• Include pressure testing and the use of leak detectors.
• Replace gaskets with original spare parts to prolong the system’s useful life.

The incident generated an additional $20,000 in repairs and penalties.

Case 2: Electrical Failure due to Use of Non-Original Spare Parts

A European operator decided to install a generic relay in a Thermo King reefer to cut costs. During the transport of vaccines at a low temperature, the relay failed because it could not tolerate voltage variations. The unit lost power intermittently, and the cargo, valued at $300,000, was rendered unusable.

Common Error:
Using non-original (non-OEM) spare parts without checking their compatibility with equipment designed for demanding marine conditions.

Lessons Learned:
Non-original electrical components are often less resistant to humidity, saltpeter (salt spray), and unstable voltages typical of ports.

Preventive Tips:

• Prioritize OEM spare parts with a manufacturer’s warranty.
• Establish a scheduled replacement plan for relays, contactors, and PCBs.
• Incorporate remote monitoring to detect electrical anomalies before they cause critical failures.

The total cost exceeded $400,000, including claims for breach of contract.

Case 3: Corrosion due to Incorrect Cleaning

An Asian fleet used saline water for the exterior cleaning of their Daikin reefers. Over time, this caused accelerated corrosion on the evaporator and chassis, leading to a rupture that released refrigerant and damaged $80,000 worth of merchandise.

Common Error:
Neglecting the correct cleaning of the reefer and using corrosive products on metallic materials exposed to the marine environment.

Lessons Learned:
The accumulation of salt and dirt drastically shortens the unit’s useful life and can generate internal breakdowns that are difficult to detect.

Preventive Tips:

• Perform periodic cleaning with suitable anti-corrosion products.
• Inspect drains and areas prone to moisture accumulation.
• Apply protective coatings to exposed structures.

The repair amounted to $15,000, a cost that could have been avoided with simple, regular routines.

Case 4: Overheating due to Overload and Poor Distribution

An African distributor loaded a reefer above the recommended limit and without respecting the ventilation channels. During a journey through desert areas, the system could not maintain airflow, and the compressor eventually overheated. The dairy products transported, valued at $100,000, spoiled.

Common Error:
Ignoring loading diagrams and blocking ventilation grilles.

Lessons Learned:
Obstructing airflow generates hot spots that overload the compressor and affect the reefer’s thermal stability.

Preventive Tips:

• Always respect the space between pallets and the air circulation guides.
• Use data loggers to record variations during the voyage.
• Train personnel in cargo simulation models to avoid invisible risks.

Conclusion: Prevention is the Best Investment

These cases demonstrate that the most costly breakdowns are often the most avoidable. Implementing rigorous inspections, using original spare parts, and applying good loading and cleaning practices reduces failures, extends the useful life of the units, and protects the cargo.

At DEPOTZF, we support our clients with technical advice, supply of original spare parts, and predictive maintenance programs to maximize the efficiency of their equipment.

If you want to prevent your company from being the next case study, contact us and we will help you strengthen your Reefer fleet.