Passive Cooling to Extend the Life of Reefer Trailers
The Challenge
How can aging reefers match the performance of new models, without the capital cost of replacement?
Aging refrigerated trailers lose insulation performance over time, forcing units to burn more fuel, run longer hours, and risk cargo integrity. For fleets extending the life of their assets, this leads to rising operating costs and higher emissions.
The Solution - PolyFrost
PolyFrost, ChillSkyn’s passive cooling coating, was spray-applied to the roof of a 2018 Utility 3000R refrigerated trailer and tested against a 2025 Utility 3000R control unit under identical load conditions.
PolyFrost is engineered to reflect solar heat, maintain cooler roof surfaces, and reduce thermal transfer into the refrigeration system.
PolyFrost
PolyFrost is a spray-applied, passive radiative cooling (PDRC) coating designed for sun-exposed surfaces in transport and industrial applications.
Reflects Solar Radiation
Reduces surface heating.
Maintains Cooler Interiors
Without adding additional energy demand.
Scalable and Easy to Apply
Using standard spray equipment, just like paint, in under 12 hours.
Effortless Maintenance
Regular cleaning with soapy water ensures long lasting peak performance.
Results
Field Trial
- Las Cruces, NM - 2025
- Test Units: 2018 Utility 3000R vs 2025 Utility 3000R (control)
- Load Simulation: 2,700 gallons of water in totes at 38°F (3.3°C) setpoint
To learn more, read the independent third-party testing certification from MVT Solutions: https://www.m-v-t-s.com/certified-technology/aerodynamics/chillskyn-trailer/
Test setup Las Cruces, NM, 2025 – 2018 Utility 3000R Units – Bare aluminum (L), Coated with Polyfrost (R) 
Thermal Image of a PolyFrost coated trailer roof – Up to 77.4°F (43°C) cooler under peak sun.
Performance Comparison | |
|---|---|
ROOF TEMPERATURE | Up to 43°C (77.4°F) cooler under peak sun (uncoated control reaching ~75°C/167°F) |
FUEL CONSUMPTION | 2018 reefer reduced from +18% higher fuel use vs. 2025 model → to within 0.3% of a 2025 unit |
ANNUAL FUEL USE | Reduced from 1,180-3540 gal/year → 1,000-3,000 gal/year (↓ 180 – 540 gal/year) |
FUEL COST IMPACT | Up to $1,895 of diesel savings per year* |
SYSTEM IMPACT | Reduced heat load on refrigeration system, improving efficiency and performance |
* At a diesel price of US$ 3.50 per gallon (2025)
Key Impacts
Immediate ROI
PolyFrost reduces solar heat gain and offsets insulation fatigue, lowering refrigeration runtime and fuel consumption. The result: up to US$ 1,895* in annual diesel savings per trailer, as well as reduces maintenance costs, with rapid payback across your fleet.
Deferred Capital Investment
PolyFrost restores thermal performance in aging trailers, helping extend fleet service life while deferring costly capital investments in new equipment. After coating, the 2018 reefer’s fuel consumption came to within 0.3% of a brand-new 2025 model, effectively eliminating the performance gap caused by aging.
Improved Resilience
PolyFrost reduces temperature fluctuations and maximizes internal temperature stability, de-risking product spoilage, giving drivers more time to respond if refrigeration system breaks down on the road.
Sustainability Gains
By reducing diesel use and extending asset life, fleets can lower their carbon footprint and support ESG goals, without adding operational complexity.