The difference between chilled and frozen transport is not just a dial setting. It affects the equipment specification, vehicle insulation, legal compliance, and what actually happens to your product if something goes wrong.
The Temperature Split
Chilled transport holds product between 0°C and 8°C. The exact setpoint depends on the cargo. Fresh meat is typically transported at 0°C to 2°C. Fresh produce at 2°C to 4°C. Dairy products at 2°C to 5°C.
Frozen transport holds product at -18°C or below. FSANZ Standard 3.2.2 sets -15°C as the legal minimum for frozen food in transit, but most operators and buyers specify -18°C, which is the international standard under Codex Alimentarius and the common threshold written into supplier contracts.
The gap between these two categories is not just temperature. It is a different physical state of the product. Chilled product is still biologically active. Bacteria can still grow, albeit slowly. Frozen product has most microbial activity halted. A chilled product delivered at 10°C is degraded. A frozen product delivered at -10°C (partially thawed) may be ruined and, depending on the cargo, unsafe.
Equipment and Insulation Differences
A chilled van and a frozen van use similar refrigeration hardware but differ in three areas.
- Insulation thickness: A frozen van needs denser, thicker insulation panels, typically 75mm to 100mm polyurethane foam, compared to 50mm to 60mm for a chilled-only setup. More insulation adds weight and reduces usable cargo volume.
- Refrigeration unit capacity: Pulling a cargo space from ambient to -18°C and holding it there requires a more powerful unit than maintaining 4°C. A unit rated for chilled use only will not achieve frozen temperatures and will burn out trying.
- Door seals and floor specification: Frozen applications require higher-grade door seals that tolerate repeated temperature cycling without cracking. The floor must handle condensation from freeze-thaw cycles during loading.
Auto Frigo specifies insulation and unit pairing based on the actual operating temperatures required, not a generic “frozen” or “chilled” label. A van used for vaccine transport (2°C to 8°C) has different requirements than one carrying beef at -1°C, even though both are technically chilled.
Which Industries Use Each
- Chilled Transport: covers fresh produce, dairy, fresh meat, seafood, cut flowers, most pharmaceuticals, chilled ready meals, and fresh bakery.
- Frozen Transport: covers ice cream, frozen seafood, frozen meat, frozen ready meals, ice, and some research and medical samples.
Some businesses need both. A food service distributor delivering to restaurants might carry chilled sauces, fresh proteins, and frozen desserts on a single run. That requires a multi-temperature van with separate zones, not a compromise setpoint in the middle.
Regulatory Requirements in Australia
FSANZ Standard 3.2.2 applies to food businesses, including transport operators moving food product for hire. The obligations include keeping records of temperature, having equipment capable of maintaining required temperatures, and not placing food at risk of contamination during transport.
The Therapeutic Goods Administration (TGA) sets separate requirements for pharmaceutical product transport under the Australian Code of Good Wholesaling Practice. Most pharmaceuticals require 2°C to 8°C (chilled), with some biologics and vaccines requiring strict logging with calibrated data loggers.
Temperature monitoring devices, mandatory data logging, and documented calibration are all more commonly required for pharmaceutical chilled transport than for standard food chilled transport.
Cost Difference
A frozen van conversion costs more than a chilled setup because of the heavier insulation, more powerful unit, and reinforced door hardware. Based on current market rates from Auto Frigo, a standard small van chilled conversion (single zone, 2°C to 8°C) starts from approximately AUD $5,000 installed. The equivalent frozen conversion (-18°C to -25°C) starts from approximately AUD $7,500 to $9,000, depending on the insulation specification and unit brand selected.
FAQs
Can a chilled van be converted to frozen?
Sometimes, but not always. If the existing insulation is under 60mm, it will need to be stripped and replaced, which is a full rebuild. If the refrigeration unit is chilled-rated only, it will need replacing. If the existing installation is less than 3 years old with 75mm panels and a compatible unit, a compressor upgrade may be sufficient. Auto Frigo can assess this on inspection.
What happens if a frozen product partially thaws in transit?
Refreezing thawed product degrades texture, increases drip loss in meat, and in some categories creates food safety risk. Ice crystal formation during the initial freeze ruptures cell walls. A second freeze after partial thaw causes further damage. Most commercial buyers and retailers reject any product that shows evidence of partial thaw, regardless of whether the final temperature was correct.
What temperature should a chilled van be set to for fresh produce?
It depends on the produce. Leafy greens: 1°C to 4°C. Stone fruit: 0°C to 2°C. Bananas and tropical fruit: 12°C to 14°C (they suffer chilling injury below 10°C). A single setpoint van is not ideal for a mixed fresh produce load. For businesses regularly carrying mixed lines, a multi-temperature setup with separate zones is worth the investment.
Is -15°C the same as frozen?
Under FSANZ it meets the legal minimum, but -15°C is not the industry standard. Most commercial buyers, retailers, and export contracts specify -18°C. Running at -15°C to save energy may create compliance issues with your customers even if it meets the legal threshold.
