Passive Cooling for Specialty Trailers - TV Broadcasting
The Challenge
How to reduce thermal load and A/C maintenance on specialty trailers, without added energy consumption?
Sports broadcasting fleets face high internal thermal loads from their complex production equipment. Combined with constant solar exposure, this forces onboard air-conditioning units to work overtime to keep interiors cool. As a result, cooling systems often require frequent maintenance and on-demand technician support. While insulation helps retain chilled air and maintain comfort for production crews, it also traps heat generated by the equipment itself, making thermal management even more challenging.
The Solution - PolyFrost
PolyFrost, ChillSkyn’s passive cooling coating, was spray-applied over a pre-existing solar reflective competitive coating product on the main roof of a 53′ broadcast trailer, and on the bare aluminum roof of its expando units.
PolyFrost is engineered to reflect solar heat, maintain cooler roof surfaces, and reduce thermal transfer into vehicle interiors.
What is PolyFrost®?
PolyFrost is a patented spray-applied passive cooling coating, engineered to reduce heat load on sun-exposed assets, such as refrigerated transport, containers, and industrial equipment.
Reduces solar heat load
Prevents surface heat from becoming an internal temperature problem.
Lowers cooling workload
Cooling systems run fewer hours. Less runtime, less energy, less mechanical strain.
Scalable and easy to apply
Standard spray equipment, just like paint, in under 12 hours. Retrofit or factory spec.
Protects asset economics
Supports resale position, maintenance planning, and replacement timing.
Results
Field Trial
- Hodgkins, IL, USA - June 5, 2025
- Peak solar radiation: 12:00 - 13:00 | 800 - 850 W/m2
- Outdoor temperature 22 - 23°C (73°F)
PolyFrost coated trailer roof – 62°F (18°C) 
Non-PolyFrost trailer roof – 101°F (39°C)
Performance Comparison | |
|---|---|
Roof surface temperature Competitor coating | 39 – 42°C (101 – 107°F) |
Roof surface temperature POLYFROST coating | 18 – 19°C (62 – 66°F) |
POLYFROST surface temperature reduction | Up to 24°C (43°F) |
Key Impacts
Improved Interior Comfort & Equipment Protection
PolyFrost helps heat escape through the roof, lowering internal temperatures. This enhances crew comfort and protects electronics from thermal stress, extending their operational life.
Reduced A/C Load & Energy Use
By cutting solar heat gain, PolyFrost eases the workload on A/C units, reducing energy consumption, maintenance needs, and fuel use in high-heat environments.