eTRU Conversion Guide

SAFECONNECT ®

SIX pins for safety

(844) 787-2332
info@safeconnectsystems.com
 (844) 787-2332
info@safeconnectsystems.com

eTRU Conversion Guide with Case Study

So, you’re thinking about electric standby? Great! The conversion to electric transport refrigeration units
(eTRUs) is an investment in your employees, your equipment, and your bottom line. In addition to the financial
benefits, you’ll also be reducing your environmental impact and getting ahead of pending legislation that
may make electric standby necessary. As with any investment, it’s important to do a thorough study to
understand the full costs and savings of the transition, as well as to accurately predict how long it will take to
get a return-on-investment (ROI).

Consider these six commonly overlooked components of electric standby to ensure your eTRU conversion is
efficient and effective—with no unwanted surprises.

1. Electrical Capacity
The first, and perhaps most critical question to ask yourself is, “do we have enough electrical capacity
to convert?” While converting to electric standby significantly reduces fuel costs, the conversion
will increase your electricity consumption. While this shouldn’t impact your ROI (see the “fuel costs”
section below), it’s important to understand whether the current on-site electrical capacity can handle
the additional load.

Not enough power? Don’t panic. Utility companies are often willing to provide funding to help defray,
or cover in full, the cost of additional infrastructure or transformers needed to handle the conversion.
In any case, be sure to let your utility know you are making the switch. You’ll want to ensure they have
the extra capacity you need available during the time of day you need it.

2. Infrastructure
If you are considering a conversion to eTRUs, you’ve probably already considered the cost of
purchasing hybrid reefer units, but don’t forget to account for facility upgrades needed as well—
things like access to 3-phase power at dock doors and trailer staging areas.

If you don’t have 3-phase power available now, it can be easily retrofitted or can be incorporated
into new construction. Be sure to contact an electrician to understand any costs that would be
associated with getting power to the necessary locations. There are different docking station
configurations available for dock door or pedestal stations. Research the options and plan out which
configuration will work best for your facility and daily company operations.
3. Fuel Costs
Fuel costs are another incredibly important item to review when considering converting to an
electric standby system. The average TRU will burn .8/gallons of diesel per hour, whereas an
eTRU uses only 8.1 kilowatts of electricity per hour. Using the average diesel and electricity costs
from December 2018, that’s a savings of $1.63 per hour per vehicle ($2.50 per hour for diesel,
compared to only 87 cents for the equivalent in electricity).

Electricity prices are historically lower than diesel and have also proven to be less volatile. Consistent
pricing makes planning and budgeting for expenses easier and more predictable.

In addition to fuel costs, idling is also a significant contributor to maintenance costs. Idling diesel
engines have considerably higher costs than idling electric motors. Research shows that most
companies significantly underestimate how often TRU idling occurs at their facilities, and the
associated cost. Want to get a more detailed understanding of the potential savings? Use this
electric standby Savings Calculator.

If you’d like to see real results from a company that has already made the switch to eTRU, scroll below
to the Case Study Results: Significant Cost Savings in One Year.

4. Equipment Costs
Equipment costs for eTRUs may seem like a pretty straightforward line item to calculate,
but it can be easy to overlook smaller items like:
• The plug and wiring on the truck or trailer
• Labor to modify trailers
• The placement of barriers to protect equipment
• Replacement of scarred or damaged plugs due to human error

Historically, the standard for connecting electric standby equipment has been a 4-pin twist lock
plug with throw arm on/off controls. One of the most common issues associated with legacy
equipment is the accidental drive-off. If a driver forgets to unplug before driving away the plug
and/or cord is ripped off the wall, creating a dangerous scenario for human contact with high-
voltage live wires and the need for expensive equipment repairs. For these reasons, it is critical
to think about how you plug in. SafeConnect offers a new safety standard for eTRU connection
systems, with a six-pin plug and tension release mechanism. In the event of an accidental drive-
off, the tension release automatically ejects the receptacle from the trailer and the control system
instantly shuts off all power in the plug, the cable, and at the box.

When considering equipment expenses, it’s also important to consider the lost opportunity
cost of NOT plugging in your trailers. Things like:
• Higher fuel costs
• Additional maintenance costs from longer run times on the diesel engine
• Non-compliance with potential future regulations
• Increased carbon footprint

All of these can be expensive and often help to justify the initial equipment cost.
5. Safety and Training
While electric standby is a benefit to your bottom line, human error associated with high voltage
electricity poses dangers that should be addressed with both proper equipment and training. The
design of SafeConnect’s plug includes two extra pins which govern a safety control circuit. That control
circuit prevents the system from being energized until the plug and the receptacle are joined together.

Another safety concern with electric standby is high voltage arcing. Arcing commonly occurs
when disconnecting traditional 4-pin systems under load. This can cause injury to employees and
plug scarring. Scarred plugs often lead to voltage drop and amperage issues that can damage or
compromise equipment. With SafeConnect’s six-pin system, arcing is virtually eliminated, reducing
equipment replacement costs and keeping employees safe.

All end users (including drivers, yard jockeys, and store associates) should be familiar and comfortable
with the high voltage connection system. Using a demo system on site prior to installation is an ideal
way to train employees ensuring they have experience with the product before using it in the field.

The SafeConnect system’s innovative six-pin design offers the necessary safety redundancy for high
voltage electric standby systems to protect your people, your equipment, and your bottom line.

6. Capital Investment
Finally, you’ll need to consider whether you have the capital available to complete the project. You
may find that it makes sense to spread out the investment over several years. You may also be able to
supplement available funds with grants and incentives from state and federal agencies.

The Environmental Protection Agency (EPA) has developed a list of SmartWay®-verified technologies
that have created significant efficiencies and improved the environmental impact of the trucking
industry. Products with the SmartWay designation have undergone a rigorous testing and evaluation
process to earn the designation.

Applications for certain grants such as those funded by the Diesel Emissions Reductions Act (DERA)
may require the adoption of EPA SmartWay or CARB verified technologies in order to be eligible
for funding.

In addition to federal, state, and local funding, utility companies offer incentive programs to help
defray the initial costs of setting up an electric standby operation. To learn more, contact your
local utility provider.
eTRU Conversion: A Case Study

Sometimes the best way to see what switching to eTRU might mean for your business is to take a look
at conversion through the lens of a company that has been through it. In 2018, Labatt Food Service
converted to eTRU. Here is their story.

With over 1700 employees and over $1.3 billion in sales, Labatt Food Service, headquartered in
San Antonio, Texas, is the tenth largest foodservice distributor in the nation, servicing food-away-
from-home customers in five states. It has five distribution centers—four in Texas and one in New
Mexico—with a fleet of 300 trailers.

The Challenge: Maximizing Equipment Life Cycles

With 100% of the company’s food distribution business delivered by refrigerated transport, the
company’s trailers were outlasting the traditional diesel-run refrigeration units. The reason?
The refrigerated units staged in the yard were idling on diesel excessively, leading to a
shortened life of the reefer unit.

It was at this point that Senior Analyst and Routing Manager John Cole realized that converting to
eTRU would drive serious cost savings for the company. “There was so much engine run time we could
save if we plugged in. Transforming that into cost savings seemed pretty straightforward,” he notes.
Armed with real data, he began to research a system-wide conversion to eTRU. This would entail a
thorough review of process and capital investment.

The Solution: eTRU and SafeConnect

Because the electric standby connection is a critical component of the infrastructure and impacts
other decisions including equipment and facility design or upgrades, it was one of the first decisions
Labatt made. After exploring four-pin plug in systems, Labatt learned about the six-pin technology of
SafeConnect. Cole delved into the science and design of the six-pin system and realized it would be
the best choice for Labatt.

After seeing the SafeConnect demonstration, Labatt decided that the new SmartWay® verified
technology aligned well with Labatt’s innovation mission and high standards for safety. Said Cole,
“After the demonstration it was pretty clear that how you plug in matters; both from a safety standpoint
and to help ensure the life of the units.”

In just 18 months, Labatt deployed SafeConnect docking stations at the first of five distribution centers
and made ready for the arrival of 75 new eTRU equipped trailers to service its South Texas customers.
The company will continue with its system-wide eTRU conversion over the next four years, outfitting its
remaining four distribution facilities and associated truck yards at a rate of one per year.
The Results: Significant Cost Savings in One Year

In its first year since making the initial eTRU conversion, Labatt Food Service is already reaping
the benefits of its decision. Results include:
• 25–30% reduction in diesel idling time
• 20% reduction in energy costs (diesel vs. electric)
• $1,300 –$1,500 per trailer per year
• $450,000 in energy savings per year (upon completion of the conversion of entire fleet)
• Alignment of purchasing cycles for TRUs and trailers
• 536,234 pounds of savings in greenhouse gas emissions per year
• 30% increase in the run life of the TRU
• 53% reduction in greenhouse gas emissions produced per hour
• 20% decrease in maintenance costs

Making the Switch to eTRU

Making the switch to electric standby is a big move and with careful planning it can provide a
quick and impressive ROI. Talk to the experts at SafeConnect today for a clear and safe path
to electrification.

(844) 787-2332
info@safeconnectsystems.com

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