Chapter 7 Actions During and After Completion of Loading Perishable Products into Refrigerated Spaces for Export

1. Containerised Shipments

Containerised sea shipments from South Africa are conducted using integral refrigerated containers (reefers), following the discontinuation of the ducted (porthole) system in 2004. This chapter addresses only integral containers, which must be technically prepared (pre-tripped) before every loading.

1.1 Loading of Refrigerated Containers

1.1.1 Verification of Loading Documents

Two types of container loading documents are used:

• CTO (Container Terminal Order): Used for container loading in the port area.
• TPD (Transport Document): Used for container loading at various inland depots.

These documents are critical as they contain all relevant cargo information, temperature requirements (reefer code), fresh air ventilation, and loading details, linking this information to a specific container. This information is used throughout the cold chain and must be absolutely correct.

Key requirements:

• No container may be loaded without a valid CTO or TPD.
• No changes may be made in writing on the document.
• Only original transport documents issued by the shipping line are acceptable.

The person in charge of loading must verify that all relevant information is entered and correct. Special attention must be given to:

• The container temperature set point (must match CTO/TPD).
• Stickers confirming the container passed cleanliness and pre-trip inspection (PTI) must be intact.
• Fresh air ventilation must be set according to CTO/TPD by the container depot.
• The product specified in the loading documents must be loaded into the correct containers as identified in the documents. Never switch cargo and containers.

Note: Only the shipping line may make changes to the transport documents or container settings. If a discrepancy is detected, do not load the container; request the shipping line to rectify the problem.

1.1.2 Installation of Special Equipment

Special carrying conditions such as controlled atmosphere (CA) and in-transit cold treatments require the installation and calibration of special instruments. Only authorized technicians of the CA supplier may install CA equipment. For in-transit cold treatments, the entire cold chain process, including calibration and installation of temperature sensors and recording devices, is supervised by an authorized PPECB official.

1.1.3 Product Loading

Follow PPECB product handling procedures:

• The product must be precooled to the carrying temperature unless otherwise indicated in writing.
• Product temperatures must be taken during loading and recorded in prescribed documents (PPECB ISO 9001-2000 Handling Protocols).
• Maximum loading temperature tolerances must not be exceeded. PPECB will reject all cargo outside the temperature specification.
• Only square and stable pallets may be loaded. No floor openings between pallets are allowed; cover any gaps to minimize cold air short-circuiting.
• No cargo may extend beyond the horizontal (ceiling) and vertical (door) red load lines.
• Container loading must be completed within 30 minutes to reduce temperature increases and condensation on the product and packaging.

1.1.4 Commencement of Recooling

Loaded containers must be connected to a power source as soon as possible after loading. The maximum Time Temperature Tolerances (TTT) must never be exceeded (see Chapter 8, par 3). Note: a TTT of 6 hours is cumulative, not per break in the cold chain. Example breakdown:

• Cold store to completion of loading: 1 hour
• Transport to port terminal: 2 hours
• Port handling: 1 hour
• Port terminal to cooling on vessel: 2 hours
  Total: 6 hours

Transport of containers with perishable products without cooling to the port must not exceed 2 hours. Use power generators (gensets) if transport time exceeds 2 hours. Deviations are only possible under special conditions and with PPECB approval. Immediate recooling must be applied as soon as the container arrives at the port terminal and again when taken on board.

1.2 Loading of Ventilated Containers

Different types of ventilated containers are discussed in Chapter 4, par 7. Ventilated shipping of perishables carries certain risks due to changing product characteristics and environmental conditions.

1.2.1 Products That Can Be Shipped Ventilated

Ventilated shipping is restricted to voyages of no more than 12 days (e.g., West/East Africa, Indian Ocean Islands). Only some products can be shipped ventilated:

• Onions and garlic (as far as Western Europe, 18 days) if waste potential is low and positive air circulation is applied.
• Potatoes (in knitted jute or polypropylene bags) to Indian Ocean Islands and West Africa.
• Early season oranges and lemons (not soft citrus or grapefruit) to Indian Ocean Islands and West Africa. Ventilated citrus shipment is not recommended after October.
• Some pumpkin varieties.

Note: Eggs may not be shipped ventilated.

1.2.2 Loading Patterns

• Allow maximum fresh air circulation throughout the load.
• Use horizontal and vertical air plenums (chimneys) to assist convection air circulation, reducing hot spots and condensation.
• Preferably palletize cargo; if break bulk, place a layer of pallets on the floor. Forklift openings must run lengthwise for unobstructed air plenum.
• Dunnage (at least 100mm) can be used instead of pallets.
• Place wooden pallets vertically against the bulkhead for vertical air movement.
• A horizontal layer of pallets in the middle of the load is recommended to create an air plenum.
• Leave at least 200mm between the top of the cargo and ceiling for a chimney effect.
• Do not exceed the maximum permissible mass.
• Store all ventilated cargo containers under cover with doors open for maximum fresh air circulation.

1.2.3 Cargo Protection

• Store loaded containers under cover with doors open and well-ventilated.
• Do not store loaded open-door containers for more than 4 days before vessel departure (to ensure the maximum storage period of 14 days is not exceeded).
• Water must never enter the container; close doors during rain or inclement weather.
• Open-door containers are only allowed under deck if PPECB is satisfied with at least one complete fresh air change per hour and at least 90 air circulations per hour.

1.3 Handling of Refrigerated Containers Prior to Shipment

Containers may be loaded and kept at an inland depot or taken to a port terminal. The following applies to both:

1.3.1 Container Terminal Checks

• Recooling must commence immediately on arrival at the terminal; TTT specifications must be applied.
• Verify requirements in transport documents (CTO/TPD).
• Check temperature set points and fresh air ventilation.
• Ensure the container is in good condition, with no external damage.
• The cooling unit must operate within design parameters.
• Check and record temperatures at least every four hours, correlating with CTO/TPD.
• Call the authorized shipping line technician for adjustments or repairs.
• Leave the container on cooling until pick-up for transport to the vessel.

1.3.2 Corrective Actions

• Report any cooling unit malfunction or incorrect settings immediately to:
  • Shipping line (for mechanical issues and settings)
  • PPECB port office (for corrective actions in collaboration with the product owner)

Containers handled or loaded incorrectly, or not operating within transport document specifications, must not be shipped.

1.3.3 Uncoupling Prior to Shipment

Containers must remain on cooling until ready for direct transfer to the vessel.

1.3.4 Communication of Information and Records

• Keep accurate records of container movements (arrival/departure times and dates, power supply/failures, temperature readings).
• Communicate temperature and other information to PPECB for temperature management during the voyage.
• PPECB may reject containers not operating within parameters or handled outside specifications and must inform the cargo owner of discrepancies and corrective actions.

1.4 Handling of Ventilated Containers Prior to Shipment

• Protect cargo from the elements at all times.
• Keep ventilated containers dry, shaded, and stored to allow maximum fresh air circulation.
• Protect against chemical, rodent, and other pollution.
• Do not store ventilated perishable products for more than 4 days in the terminal before shipping.
• Remove and destroy or sell on the local market any containers rejected due to contamination or over-storage.

1.5 On-Board Checks Prior to Departure

On-board checks of containers, decks, and cargo during and after loading are crucial. This is the final opportunity to ensure all systems function within specifications.

1.5.1 Refrigerated Containers

• Connect integral refrigerated containers to a suitable power supply as soon as possible, but not more than one hour after landing on board.
• Carrying temperature instructions (reefer code) as audited by PPECB must be applied at all times.
• The Master must have PPECB reefer code definitions and apply the correct carrying conditions.
• Verify container settings (temperature set point, delivery air temperature, fresh air ventilation) according to the reefer code before sailing.
• Only authorized shipping line personnel may make adjustments.
• Log and immediately report all deviations and corrective actions to PPECB for further steps in consultation with the grower and shipping line.

1.5.2 Controlled and Modified Atmosphere Containers

• The internal atmosphere of CA and MA containers differs from normal. Special controllers manage the gases inside.
• Ensure fresh air intake valves are set according to the reefer code.

1.5.3 Ventilated Containers

• May only be stowed under deck if the air circulation rate is at least 90 (preferably 120) complete air changes per hour.
• On-deck ventilated containers must be protected from sea spray and seawater.
• Always stow ventilated containers to protect against the elements and contamination from bunkers, diesel, exhaust, and other gases.
• Ensure an adequate supply of clean, cool fresh air. Do not stow ventilated containers next to integral refrigerated containers (to avoid hot air contamination).
• Some ventilated containers have extraction fans, which must be connected to a suitable power supply.

2. Conventional Refrigerated Shipments

Conventional shipments from South Africa include:

• Conventional refrigerated shipments
• In-transit cold treatments in conventional decks
• Ventilated shipments under specific conditions

In-transit cold treatments are an integral part of conventional refrigerated shipments but require stricter temperature maintenance.

2.1 Loading Plans

• Products shipped at the same temperature regime (reefer code) for the entire voyage may be stowed together in the same deck, provided there are no taint risks.
• Products requiring different temperature regimes must be shipped separately (especially avocados, mangoes, plums).

2.2 Temperature Maintenance During Loading

2.2.1 Temperature Measurements

• Product temperatures must be taken frequently and at various stages/positions.
• At least 20% of the total load (one out of every ten pallets) must be checked and recorded during loading.
• Include regular checks of products in the cold store or pallets delivered to the quayside.
• During deck loading, check both the core (via thermocouple) and outside of pallets.

2.2.2 Temperature Increases

• Only load pallets within specified temperature tolerances.
• Close hatches and start recooling as soon as the temperature of already stowed produce reaches or exceeds the tolerance.
• For produce in polyethylene bags, center temperatures should never increase during loading.
• For ventilated cartons (e.g., stone fruits, avocados, mangoes), center temperatures may increase by a maximum of 3°C before recooling (see PPECB protocol and Chapter 8, par 3.4.2).
• Report all temperature deviations to PPECB for management procedures.

2.2.3 Crane Feeding Rates

• Do not delay pallets with cooled produce on the quayside.
• Cranes must be fed at the same rate as loading.
• If equipment breaks down, return pallets to the cold store for recooling.

2.2.4 Recooling During Breaks

• No pallets should be in air locks or on the quayside during tea/lunch breaks.
• Close decks and apply cooling during breaks longer than 30 minutes.
• High humidity in port areas (80–100% RH) means moisture will condense quickly on cold surfaces, promoting spoilage and carton collapse.

2.2.5 Protection of Cargo

• Protect perishable cargo from the elements and pollution during and after loading.
• Avoid exposure to sun, wind, exhaust gases, petroleum fumes, or other cargo.
• Do not load during rain or if the atmosphere contains dust or chemicals.

2.3 Stowage of Refrigerated Perishable Products

2.3.1 Heat Leakage and Air Circulation

• Some deck positions are exposed to more heat leakage (e.g., above heated bunker tanks, engine room bulkhead, bow).
• Ensure sufficient cold air circulation to these areas.
• Stack a vertical row of pallet bases against the engine room bulkhead for extra vertical air circulation.

2.3.2 Loading Configuration and Air Circulation

• Ensure adequate air circulation through the load.
• Provide an unobstructed return air plenum (minimum height 150mm).
• Pallet height must not exceed 2.1m at loading.
• Never load cargo above the bottom level of air return openings.
• Tightly stow pallets and block all vertical openings between pallets (air bags are effective).
• Ensure all 2-way pallet base openings face the air supply direction.

2.3.3 Damaged Pallets and Cartons

• Remove and fix all broken pallets.
• Use walking boards when walking on pallets to protect cargo and keep cartons clean.
• A single footprint on cargo is grounds for rejection under food safety regulations.

2.3.4 Traceability

• Keep accurate records of pallet identification and stowage position for traceability.

2.3.5 Sealing of Hatches

• Replace hatch covers and commence cooling immediately after loading.

2.4 Reaching Carrying Conditions

2.4.1 Carrying Conditions

• The Master must ensure carrying conditions are correctly understood, set, and applied:
  • Temperature set point and air delivery temperature per reefer code.
  • Fresh air ventilation to keep CO₂ below 0.5%.
  • Maintain controlled atmosphere conditions as specified.
  • Record all temperatures and related information.
  • Inform PPECB of any deviation from the specification.

2.4.2 Recooling Times

• Recooling must start immediately after loading. Guidelines:
  • Citrus fruit (all precooled): 12 hours; non-precooled: 6 days
  • Deciduous fruit (packed in polibags): 12 hours; not in polibags: 4 hours
  • Frozen produce: max 3 hours
  • Subtropical fruit: max 4 hours

3. In-Transit Cold Treatment Shipments

Some countries require in-transit cold treatment to eradicate quarantine insects. Requirements differ by country and insect, and are agreed bilaterally between the exporting and importing countries’ Departments of Agriculture. PPECB is the authorized local supervising and certification authority.

Key requirements:

• The entire load must be precooled to below -0.5°C before loading.
• Product temperature increases during handling/loading are limited to a maximum of +2°C.
• Treatment starts only when the specified product temperature is reached.
• If product temperature rises above the requirement, treatment is cancelled and must restart.
• Some countries specify maximum air temperatures and defrost conditions.

3.2 Treatment Duration

• Cold treatment periods vary from 12 to 22 days, depending on the insect.
• Some countries use a sliding temperature/time scale for small temperature increases (mainly during defrost).

3.3 Temperature Recooling Requirements

• Product and air temperatures must be recorded continuously.
• Final approval is based on treatment temperature data.
• Use approved, calibrated temperature measuring and recording devices.
• Install sensors in specified positions.

3.4 Temperature Checks Prior to Sailing

• Check all temperatures, recorders, and settings before sailing to allow last-minute adjustments and prevent rejections.

3.5 Certificates Required

PPECB issues the following certificates:

• Cold store registration certificate
• Precooling certificate
• Instrument calibration certificate
• Product loading temperature certificate

Some countries may require additional certificates. It is the exporter’s responsibility to ensure certificates are delivered to the importing country’s authorities before product arrival.

4. Ventilated Shipments of Perishable Products

Technical requirements for ventilated conventional shipments are discussed in Chapter 5, par 5. Products and conditions for ventilated container shipments are discussed in Chapter 7, par 1.2.

4.1 Risks Involved in Ventilated Shipments

Ventilated shipments are not recommended due to uncontrollable risks:

• Products like onions and potatoes cannot tolerate warm temperatures and high humidity, leading to quality losses.
• Preshipment, transshipment, and post-discharge conditions are unpredictable and uncontrollable, complicating dispute resolution.

4.2 Fresh Air Circulation

• Continuous fresh air ventilation (90–120 complete air changes per hour) is required.
• Marine air is often very humid; moisture may condense on the product.
• Avoid introducing air colder than +5°C or warmer than 25°C.
• Aim to keep product temperature between +15°C and +20°C.

4.3 Cargo Protection – Food Safety

• No chemical pollution allowed; stow perishables in separate spaces.
• No physical contamination (metal, glass, wood, sand, dust).
• Decks must be clean before and during loading/voyage.
• No microbiological contamination (rodents, remains of previous cargo, water intrusion).

4.4 Cargo Protection – Product Quality

• Never stow cargo near heat sources.
• Ensure adequate airflow through and around the load.
• Stabilize cargo to prevent movement during voyage.
• Never handle cargo directly on the quayside surface; protect after discharge.

5. Shipping Information

All shipping information must be delivered to PPECB in the format and times specified in PPECB regulations. Failure to comply may result in legal action or refusal to load the vessel in a South African port.

Required information:

• Reefer lists for containerized shipments
• Stowage plans (including reefer code) for all conventional shipments
• Bills of lading within 5 days from departure