Automated Data Catcher Use Case #4 - Reefer Monitoring and Energy Consumption Analytics

Introduction

This document outlines the Automated Reefer Monitoring solution developed by Gelectric. The primary objective of this solution is to provide precise visibility into the energy consumption of refrigerated containers (reefers). By using the Automated Data Catcher to extract reefer counts and power status from unstructured logs, we enable operators to accurately calculate auxiliary energy loads, justify energy surcharges, and optimize the vessel’s electrical balance.

Background

For container ships and multi-purpose vessels, reefers are the most energy-intensive cargo on board. Monitoring their impact is a significant challenge because reefer "plug-in" and "unplug" events are often recorded in manual deck logs, manifests, or informal Excel sheets. Without a structured way to track these numbers, it is nearly impossible for the head office to distinguish between the fuel consumed for basic vessel operations and the fuel consumed specifically to maintain the cold chain.

Problem Statement

The primary challenges identified in reefer energy management include:

• Hidden Costs: The high fuel cost of running auxiliary engines for reefers is often "buried" in the total fuel bill, making it hard to bill charterers accurately.

• Manual Tracking Errors: Relying on crew members to manually count and report connected reefers leads to data gaps and inconsistencies.

• Lack of Historical Data: Without a structured record of reefer loads, it is difficult to analyze the impact of different cargo profiles on the vessel's overall CII (Carbon Intensity Indicator) rating.

• Energy Inefficiency: Identifying aging or faulty reefer units that consume excessive power is impossible without correlating plug-in data with fuel consumption.

Objectives

The primary objectives of this solution:

• To automate the extraction of reefer quantities and connection durations from unstructured reports using the Automated Data Catcher.

• To calculate the specific fuel consumption (and resulting emissions) attributed to the reefer load.

• To provide clear documentation for "Reefer Surcharges" to be passed on to cargo owners or charterers.

• To improve the accuracy of the vessel's electrical load balance calculations.

• To support "Green Cold Chain" initiatives by providing transparent energy reporting.

Solution

Automated Data Catcher for Reefer Analytics

To address the identified problems, Gelectric integrates a specialized data extraction logic for refrigerated cargo:

• Manifest & Log Parsing: Automatically extracting reefer container IDs, set-points, and connection times from deck logs and stowage plans.

• Power Load Correlation: Linking the number of connected reefers to the auxiliary engine (generator) fuel consumption recorded in the Noon Reports.

• Consumption Modeling: Applying thermal algorithms to estimate the kWh consumption based on ambient temperature and reefer count.

• Automated Reporting: Generating summary reports per voyage that highlight the total energy "cost" of the refrigerated cargo.

Key Data Points Captured

1. Reefer Connection Logs: Extracting the exact number of units connected, including plug-in and unplug timestamps.Source: Daily Deck Logs & Reefer Manifests.

2. Auxiliary Engine Performance: Monitoring generator load and fuel flow during periods of high reefer density. Source: Engine Room Noon Reports.

3. Ambient Temperature Conditions: Capturing sea and air temperatures to normalize power consumption data (as reefers work harder in warmer climates). Source: Meteorological data in Noon Reports.

4. Maintenance Alerts: Flagging discrepancies where a high reefer count does not align with expected generator loads, indicating potential electrical or mechanical issues. Source: Structured comparison of Power vs. Cargo data.

Data Collection and Analysis

• Following the activation of the Automated Data Catcher, the technical and commercial teams can access:

• Reefer Energy Dashboard: A visual breakdown of "Propulsion Fuel" vs. "Reefer Fuel" for every leg of the voyage.

• Commercial Surcharge Reports: Automated data exports that justify energy billing to third-party charterers based on actual connection hours.

• CII Impact Analysis: Insights into how reefer-heavy voyages affect the vessel's annual carbon intensity rating.

• Fleet Benchmarking: Comparing reefer energy efficiency across different vessel designs or routes.

Conclusion

The Gelectric Automated Data Catcher turns reefer monitoring from a manual counting exercise into a precise financial and technical metric. By unlocking the data contained in daily logs and manifests, we provide the transparency needed to recover energy costs and optimize generator usage. As the maritime industry moves toward stricter carbon accounting, knowing exactly how much fuel is "in the fridge" is no longer a luxury, it is a commercial necessity.

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