From Customer to Delivery: Designing and Building Custom Refrigerated Solutions 

At ES Frigo we understand how important it is to turn the specific needs of each customer into tailor-made refrigeration solutions.  

From the first consultation to the final testing, our process is designed to ensure that each project reflects the practical and operational needs of the customer. 

Consultation and Needs Analysis 

The journey begins with a direct meeting with the customer, aimed at gathering all the necessary information to understand the type of product to be transported and how it will be handled.  

At this stage, we determine whether the goods are fresh, frozen, or require multiple temperature zones, and we analyse the loading and unloading methods for the vehicle. The type of vehicle to be used, whether a van, a lorry or a mobile box, is evaluated, taking into account the usable volume, the distribution of the load and the particular needs of the target sector, such as transporting meat or loading pallets. 

Technical Design 

Once the needs have been clarified, we move on to the technical design stage, which begins with the creation of a preliminary layout. This layout defines the internal space of the refrigerated body or box, the usable volumes, and the positioning of components to ensure balanced weight distribution and reduced thermal dispersion.  

At the same time, the refrigeration system is sized: we assess whether a system powered by the vehicle’s battery will suffice or whether a continuous-operation system is required, based on the type of the transport and how frequently the doors will be opened. A crucial aspect of the design concerns the construction of isothermal panels.  

These sandwich panels, consisting of a fibreglass skin and a high-density polyurethane core, are designed not only to ensure excellent thermal insulation, but also to withstand specific loads. For example, reinforced structures and metal inserts are integrated to allow secure mounting of the refrigeration unit, shelving or hanging rails – essential elements for transporting delicate or particularly heavy goods. 

Production and Assembly 

With the project approved, we finally move on to the operational phase. Production begins with the creation of individual panels, which are accurately shaped using advanced techniques.  

The processing of the polyurethane and the application of the fibreglass are carried out to create perfectly interlocking joints that eliminate thermal bridges and ensure the structural integrity of the unit. Subsequently, the panels are assembled to form the refrigerated box, a process that requires great care to ensure that all the reinforcement elements are positioned correctly.  

During assembly, the refrigeration unit is also integrated, complete with all the necessary electrical and mechanical connections, and provisions are made for the installation of any internal components such as shelving or customised racks.  

The final stage involves a series of tests and inspections to check the thermal stability, structural robustness and effectiveness of the refrigeration system, thus ensuring that the solution is ready to meet the daily challenges of transport. 

Ongoing Consultancy and After-Sales Support 

Our commitment does not end with the delivery of the finished product. At ES Frigo, we offer continuous support that includes scheduled maintenance services – ideal for maintaining the efficiency of the system in the long term. 

We recommend inspections at least twice a year, allowing for prompt intervention in the event of anomalies and ensuring compliance with operational specifications, even under varying conditions.  

In addition, we are always ready to provide updates and customisations should the customer’s needs evolve or new logistical challenges arise, adapting flexibly to market changes. 

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At ES Frigo, we combine experience, technology and attention to detail to ensure that every project we deliver is effective and built to last. 

If you’d like to find out more about how we can help you design and build the perfect solution for your business, don’t hesitate to contact us. 

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The Evolution of Refrigerated Transport: From Natural Ice to Future Technologies 

At ES Frigo we are passionate about everything related to technological innovation in refrigerated transport. Today, however, we want to take you on a journey through time — from the early solutions that used natural ice to the latest cutting-edge technologies that are transforming our industry.  

Let’s explore together the key milestones and technical innovations that have made this change possible. 

From Natural Ice to First Mechanical Innovations 

Natural Ice and the First Insulating Boxes 

Once, before there was mechanical refrigeration, the only “system” available was the collection of ice during winter.  

Ice was stored in caves or pits dug into the ground, which offered a consistently cooler temperature than the outside air. These pits were used to store meat, fish and other foods. Later, the first wooden boxes lined with ice were developed — a primitive but effective method of keeping food fresh during transport. 

The Birth of Mechanical Refrigeration 

As early as the 19th century, inventors such as William Cullen, Jacob Perkins, and other pioneers began experimenting with the first mechanical systems based on the gas compression cycle. These early systems paved the way for what would become a true revolution: the ability to create refrigerated environments autonomously and with precise control. 

After World War II, the Americans made significant contributions to the evolution of refrigeration systems by introducing compression and expansion technologies. These systems used compressed gases that, when expanded, absorbed heat from the environment, allowing the air to be cooled and the temperature of products to be maintained consistently. 

Modern Technologies and Technical Innovations 

From the Use of Polluting Gases to Environmental Sustainability 

In the following decades, the industry made great strides forward. In the 1930s and 1940s, synthetic refrigerants like Freon, were introduced which initially made it possible to have more compact and efficient systems. However, the discovery of the environmental impact of these gases, responsible for the ozone layer depletion, prompted the entire sector to look for greener alternatives.  

Today, refrigerants such as propane and ammonia are preferred, offering good performance with a lower impact on the environment, although they come with safety and regulatory restrictions. 

The Advent of Digitalisation and Remote Monitoring 

One of the most significant innovations in recent years has been the integration of electronics into refrigeration systems.  

With the introduction of sensors and remote monitoring devices, it is now possible to control the temperature and status of systems in real time, preventing malfunctions and responding promptly to any anomalies. 

It is not just a matter of “following a trend”, but of concretely exploiting technology to guarantee the quality of the product throughout the entire journey. 

Innovations in Design and Energy Management 

In recent times, the focus has also been on energy efficiency. Modern refrigeration systems are designed to optimise energy consumption, reducing costs and environmental impact.  

Cold storage systems have been tested, which allow the refrigeration system to be “charged” overnight (when demand is low) and to release the cold during the day, thus ensuring thermal stability even in conditions with frequent door openings. 

The Role of Predictive Maintenance and Artificial Intelligence

Looking ahead, the future seems to be heading towards the use of artificial intelligence (AI) for predictive maintenance.  

Although still in its early stages within refrigerated transport, AI promises to analyse large volumes of data to detect faults or anomalies before they become critical. This will not only improve the reliability of systems, but will also allow for more efficient and sustainable management of resources. 

Futuristic Experiments 

Another frontier of research concerns magnetic refrigeration. Still largely confined to laboratory testing, this technology uses magnetic fields to lower the temperature, potentially eliminating the need for refrigerant gases altogether. If applied on a large scale, it may once again revolutionise the industry by making it even more sustainable and efficient. 

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The evolution of refrigerated transport is a story of ongoing innovation: from the simplicity of natural ice, to complex mechanical systems, the integration of digital solutions, improved energy efficiency and now the exciting possibilities of artificial intelligence and magnetic refrigeration. 

At ES Frigo, our experience and commitment to new technologies drives us to follow these developments enthusiastically, so we can offer increasingly high-performance, safe and sustainable solutions. 

Stay connected and keep following us: the future of refrigeration is constantly evolving and we are here to move forward on this exciting journey with you! 

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Fitting Out a Refrigerated Van: Everything You Need to Know About Technical Solutions, Timings and Costs 

If you handle perishable or heat-sensitive products, sooner or later you will have wondered how to best equip a refrigerated van. Maintaining the cold chain is essential, but solutions can vary greatly depending on your needs, budget and type of work.  

From a simple “isothermal box” to more complex systems with refrigeration units or eutectic plates, there is no shortage of options.  

Let’s take a look at the main points together. 

What do you need to use it for? 

Transport vs Distribution 
The first thing to ask yourself is whether you will be making a single trip with final delivery or a distribution with many stops.  

If you open your van a few times (for example, transporting goods directly from point A to point B), you can also settle for a less sophisticated system such as a single isothermal box.  

If, on the other hand, you need to open the cargo area frequently for deliveries to several customers, you will need solutions capable of withstanding these continual temperature fluctuations. 

What temperature do you need to maintain? 

Fresh or frozen? 
Understanding the temperature at which you want to store the product is essential. Transporting fresh goods at 0°C is different from having to keep frozen goods at -20°C.  

If you have to handle fresh and frozen products at the same time, the issue is complicated: you may need systems that manage multiple temperatures in the same vehicle. 

What vehicle are you going to use? 

Permanent fit-out or insertion of a box? 
In some cases, a cold room is permanently installed inside a van or truck. In others, all that is needed is to fit a mobile isothermal box, without modifying the vehicle in an invasive manner.  

The choice depends on the volume of goods, the frequency of use and the flexibility you need. 

Is a simple isothermal box enough? 

If you need to cover short distances and do not open the van frequently, a container that maintains the temperature for the duration of the journey (perhaps an hour or slightly longer) may suffice.  

It is an economical solution, perfect for a craftsman who transports their products from a workshop to a shop, without too many intermediate stops. 

Do you have to make long trips with several van openings? 

Level up if you need longer trips or multiple openings. A refrigeration unit powered by the vehicle battery cools the isothermal box while the engine is running. 

Ideal for maintaining 0°C over long distances or with several stops, because the temperature is easily restored after each opening. 

Large-scale distribution and subzero transport 

For those of you who have to go down to -20°C and run into battery power limitations, eutectic plate systems are available that accumulate the cold overnight.  

The eutectic liquid freezes at very low temperatures (for example -30°C), and gradually releases the cold during the day, guaranteeing thermal autonomy even without a refrigeration unit running continuously. 

These are the most complex systems, but also by far the most effective for those with special needs. 

Time and costs: two important variables 

How much does it cost? 
It is difficult to provide a standard figure: this ranges from around €1,000 for a basic system (for example a simple isothermal box) up to €30,000 for larger and more complex installations, which able to handle different volumes and temperatures.  

The price increases with the capacity, the need for active refrigeration and the presence of multiple compartments. 

How long does it take? 
On average, a fit-out can take from 5 to 7 weeks.  

This includes the design, production of isothermal parts and/or construction of refrigeration or eutectic systems, plus any fixed installation in the vehicle. 

Fitting out a refrigerated van requires careful evaluation: the type of goods, the frequency of opening, the temperatures required, the loading volume and the available budget. Often, it is an investment that pays off in terms of quality of transport and protecting the goods. 

Whether you are a small-scale producer with few deliveries or a distributor supplying dozens of outlets, there is always a tailor-made solution. And with the right planning — and perhaps some advice from experts in the field — you can guarantee optimum thermal reliability and the satisfaction of your customers (as well as your own!). 

If you need personalised support or want to find out more about configuring your vehicle, ES Frigo is here to help you find the perfect solution — whether it’s a simple isothermal box or a eutectic plate system built for the toughest routes.  

Do not hesitate to contact us: the cold is our job! 

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How to Cool an Electric Bus Without Draining the Battery 

The electric revolution has introduced many innovations in the transport sector, but if there is one aspect that often complicates the life of zero-emission vehicles it is climate control in the interior.  

A traditional air conditioner either relies on belts connected to the internal combustion engine or, alternatively, draws a large amount of power from the battery, compromising the vehicle’s range. And when the vehicle in question is a 30-seater bus, the challenge becomes even more serious. 

The problem to solve 

An air conditioning system that puts too much strain on the battery risks undermining the whole point of designing environmentally friendly electric vehicles. A number of manufacturers had tried to solve the issue by installing a small combustion engine dedicated solely to powering the air conditioning system. Unfortunately, this completely defeats the purpose of having a fully electric, zero-emissions vehicle! 

Another possible solution involved the addition of larger, bulky and expensive battery packs, not to mention the additional weight, ultimately increasing energy consumption. In short, a new, sustainable approach was needed – one that could keep both costs and battery impact to a minimum. 

Our idea 

When Iveco, a leading Italian company in the commercial vehicle sector, approached us to find a practical, efficient way to cool a passenger bus, we immediately turned to eutectic technology: a system that allows the “cold” to be stored while the vehicle is stationary, using mains electricity instead of draining the on-board batteries. How did we do it? We started with an idea that was as simple as it was effective: 

We basically used luggage racks to install tubes filled with distilled water. During the night, when the bus is connected to the power grid, the water is cooled significantly. Then, during the day, the vehicle’s internal ventilation system circulates air through these tubes, cooling the interior. In this way, the only additional energy use is for the fans – without putting any strain on the main battery. 

A project in collaboration with Iveco and the university 

This system was the result of a collaborative effort involving Iveco, The University of Eastern Piedmont and ES Frigo. European funding has made it possible to explore innovative solutions, bringing together research, engineering and sustainability. The first tests were a success – so much so that the prototype was sent to a major testing facility in Madrid, where Iveco operates cutting-edge infrastructure to test vehicle performance under extreme conditions. 

How the testing went 

At the Spanish test site, a team of researchers and technicians measured the energy needs of our air conditioning system with extreme precision. Thanks to this data, we were able to determine the number of kilowatt-hours that were needed to keep a medium-sized electric bus cool, while minimising the loss in driving range. 

The feedback was positive across the board: 

• Energy savings: much of the thermal energy was already “stored” overnight. 

• Cost reduction: no need for auxiliary engines or oversized battery packs. 

• Passenger comfort: interior temperatures remained pleasantly cool even during the hottest hours. 

Why this was a special project 

Creating a eutectic air conditioning system for a 30-seater bus was a real leap into the future. We brought our expertise in refrigerated transport into a rapidly evolving sector: electric vehicles. 

It’s not every day you get to contribute to a project that reduces CO₂ emissions while maintaining passenger comfort – all without compromising the vehicle’s range. Working closely with Iveco and university researchers allowed us to tackle unique technical challenges and gather valuable data for future developments. 

This electric bus with cold storage technology is a tangible example of how innovation can open up new pathways for sustainable mobility. And we at ES Frigo are proud to have brought our expertise to the table to help solve a real-world challenge with a practical, forward-thinking solution! 

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Keen to learn more about our technologies for green mobility? Visit the section on solutions for the electrical world on the ES Frigo website and get inspired by the sustainable revolution! 

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Handling Trout with Care: An Innovative Project for Animal Welfare 

When it comes to trout farming, we often think first of the quality of the final product or compliance with health regulations. But how often do we stop to think about how animals experience the final moments of their lives?  

The Friuli agri-food centre, together with the company Friultrota, wanted to turn this mindset on its head by contacting us with a truly revolutionary project: they wanted to ensure a more ethical slaughtering method, one that could minimise stress for the trout and optimise their welfare. 

An “ethical” slaughtering procedure 

The centre had already conducted studies on the different slaughtering techniques, discovering that animal welfare could be measured using an enzyme found in the blood of fish. More traditional methods, such as the blow to the head, yielded good results from the point of view of “speed” but did not always guarantee the highest standards of respect for the animal. This is why the idea of a “cold-induced asphyxiation” was considered, considering that trout can withstand temperatures as low as around -8 °C. 

How do you reach -10°C? 

This is where our experience comes into play. We had to design a system that would bring the water to a temperature of about -10°C, without freezing it. The basic idea? A salt-water tank (to lower the freezing point), combined with a eutectic system capable of reaching -16°C. 

But there was one important detail to consider: the water had to remain in a liquid state to allow the trout to swim, while being cold enough to induce a quick and painless “sleep”. In essence, we created a delicate balance between temperature, salinity and water recirculation, making sure that the fish didn’t experience a traumatic shock. 

The second challenge: a tank built for…600 trout! 

Keeping the water at -10° C was already a significant achievement, but the real hurdle came when the customer told us that they needed to process up to 600 kilograms of fish at a time. Imagine: hundreds of trout swimming together, raising the water temperature through body heat – and in no time, risking a loss in cooling efficiency. The tank also had to hold up to 6,000 kilograms of fish and water – a real structural challenge! 

To solve these problems, we engineered a reinforced structure, using materials suitable for supporting heavy loads without warping. In addition, we included special heat exchangers and a particularly powerful eutectic system capable of restoring the required temperature even after large batches of fish were introduced. 

An experiment in its own right 

Creating such a system on a large scale was, in every sense, an experiment. It was an experience halfway between science and engineering, involving tests and simulations to fine-tune every detail: from salt concentration, to the positioning of temperature sensors, to the monitoring of trout welfare.  

Each step was discussed with the specialists of the centre who, through blood analysis, confirmed significantly lower stress levels achieved with this slaughtering method. 

The results: animal welfare and customer satisfaction 

In the end, the system worked flawlessly: the trout, placed in this “super-chilled” water, entered a kind of dormant state before gradually dying and, according to the analyses, without peaks of stress. The customer, delighted to have found a more ethical solution, was able to confirm that the final product was of high quality, with a fresh, firm meat. 

Looking to the future 

This project is a striking example of how innovation and research can improve not only product quality, but also respect for animal welfare. More and more companies and research centres are showing interest in solutions that combine efficiency and compassion. And we’re ready for the next challenge, confident that cold chain technology can be applied in unexpected sectors. 

Whether it’s “just” trout or other animals, we believe that the desire to do better – for nature and for people – is the true driver of innovation. There’s still so much to learn, but this experience has taught us never to stop experimenting and exploring new paths. 

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Want to discover more stories where the animal world meets innovation in refrigeration? Check out our equally fascinating project involving some animals that are a bit more… furry! 

Read the full article now on our blog (link coming soon). 

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