Exploring novel carton footprints for improved refrigerated containers usage and a more efficient supply chain.

Large quantities of fresh produce are exported every year to international markets across the world using refrigerated freight containers (RFCs). However, many packaging systems are legacy designs for older shipping technologies. For fruit, more than 10% of the RFC floor area is unused by current packaging systems, and designs often do not facilitate adequate cooling conditions. This study showed that novel packaging designs could improve packing density by up to 19%. Two new packaging systems were investigated using CFD to emulate conditions similar to forced-air cooling (FAC) and a RFC, respectively. The proposed packaging increased floor area utilisation to about 98%. The FAC energy efficiency was improved by 29%. An analysis of the results indicates considerable cooling improvements are possible by modifying vent hole designs and using taller cartons. The study thus demonstrated substantial merits to implementing new fruit packaging systems. • Packaging systems were assessed using a multiparameter evaluation approach. • Design of novel packaging systems that utilise 98% of container floor area. • Cooling efficiency of forced-air cooling improved by 29% with new carton design. • Improved container cooling efficiency feasible by designing taller cartons. • New design is ergonomic, backwards compatible and improves cooling and density. [ABSTRACT FROM AUTHOR]