Refrigerated freight is highly sensitive, and even small mistakes can lead to major losses. Reefer claims are among the most expensive in trucking because spoiled or temperature‑damaged cargo often cannot be salvaged. Understanding the most common reefer claims—and how to prevent them—helps protect your business, reduce insurance costs, and maintain strong relationships with brokers and shippers.
This guide breaks down the top reefer claim types and the best ways to avoid them.
1. Temperature Deviations
Temperature deviations are the #1 cause of reefer cargo claims.
Common Causes
- Incorrect setpoint
- Using start/stop mode instead of continuous
- Poor airflow
- Door openings
- Faulty sensors
- Warm trailer before loading
How to Prevent It
- Always pre‑cool the trailer
- Verify the correct setpoint
- Use continuous mode unless the shipper specifies otherwise
- Maintain proper airflow
- Minimize door openings
- Document temperature readings throughout transit
2. Reefer Unit Breakdown
Mechanical failures can quickly lead to spoilage.
Common Causes
- Low refrigerant
- Dirty coils
- Worn belts
- Electrical failures
- Poor maintenance
How to Prevent It
- Follow a strict maintenance schedule
- Perform daily pre‑trip inspections
- Check belts, hoses, and refrigerant levels
- Clean evaporator and condenser coils
- Address alarms immediately
- Keep maintenance records for claims protection
3. Improper Loading or Airflow Blockage
Even a perfectly functioning reefer can fail if airflow is blocked.
Common Causes
- Freight pushed against walls
- Overloaded pallets
- No space between pallets
- Blocked return air chute
- Incorrect use of bulkheads
How to Prevent It
- Maintain proper spacing
- Use load locks and bulkheads
- Train warehouse staff and drivers
- Ensure cargo does not block airflow channels
4. Door Openings and Temperature Shock
Every door opening causes warm air to enter the trailer.
Common Causes
- Frequent stops
- Fueling with doors open
- Unnecessary inspections
- Poor loading procedures
How to Prevent It
- Minimize stops
- Keep doors closed during fueling
- Use seals to prevent tampering
- Load quickly and efficiently
5. Incorrect Setpoint or Mode
A simple mistake can ruin an entire load.
Common Causes
- Driver misunderstanding
- Shipper miscommunication
- Wrong temperature on paperwork
- Using start/stop mode when continuous is required
How to Prevent It
- Confirm setpoint with shipper
- Double‑check paperwork
- Use continuous mode for sensitive freight
- Document setpoint before leaving the dock
6. Fuel Shortages
If the reefer runs out of fuel, the unit shuts down—leading to spoilage.
Common Causes
- Long hauls without refueling
- Faulty fuel gauges
- Driver oversight
How to Prevent It
- Keep reefer fuel ¾ full or higher
- Check fuel levels at every stop
- Use fuel receipts as documentation
7. Sensor or Thermostat Failure
Faulty sensors can cause inaccurate readings or improper cooling.
Common Causes
- Old or worn sensors
- Electrical issues
- Poor calibration
How to Prevent It
- Test sensors regularly
- Include sensor checks in monthly maintenance
- Replace faulty components immediately
Final Thoughts
Reefer claims are costly—but most are preventable. With proper maintenance, correct loading procedures, accurate temperature control, and strong documentation, carriers can significantly reduce their risk. A proactive approach protects your freight, your reputation, and your bottom line.
More From FleetGuard USA
Related Articles
Reefer Unit Maintenance Checklist https://fleetguardusa.com/reefer-unit-maintenance-checklist
Temperature Control Requirements https://fleetguardusa.com/temperature-control-requirements
Reefer Breakdown vs Cargo Spoilage https://fleetguardusa.com/reefer-breakdown-vs-cargo-spoilage
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