1. Containerised Shipments
Containerised sea shipments from South Africa are conducted using integral refrigerated containers (also known as reefer containers), following the discontinuation of the ducted (porthole) system in 2004. This chapter focuses on integral containers. Each unit must be technically prepared (pre-tripped) prior to 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 shall be loaded without a valid CTO or TPD.
- No changes must 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:
- Container temperature set point (as per CTO or TPD).
- Stickers confirming the container passed cleanliness and pre-trip inspection (PTI) must be intact.
- Fresh air ventilation must be set according to CTO or TPD by the depot.
- The product specified in the 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 and 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 installation and calibration of special instruments:
- Only authorized technicians of the CA supplier may install CA equipment.
- In-transit cold treatments require the entire cold chain process, including calibration and installation of temperature sensors and recording devices, to be supervised by an authorized PPECB official.
1.1.3 Product Loading
Follow PPECB product handling procedures:
- 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 cargo outside the temperature specification.
- Only square and stable pallets must 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.
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). TTT is cumulative, not per break. Example breakdown for a 6-hour TTT:
- 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 allowed under special conditions and with specific products, and only PPECB can approve a deviation after considering all relevant product quality factors. Immediate recooling must be applied at the port terminal and again when the container is 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-day voyage) if waste potential is low and positive air circulation is applied.
- Potatoes packed 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 shipment of citrus is not recommended and only allowed until end October.
- Some pumpkin varieties.
Note: Eggs may not be shipped ventilated.
1.2.2 Loading Patterns
Allow for maximum fresh air circulation throughout the load to maintain product temperature in equilibrium with ambient conditions. Use horizontal and vertical air plenums (chimneys) to assist convection air circulation, reducing hot spots and condensation.
Key considerations:
- Preferably palletize cargo; if break bulk, place a layer of pallets on the floor. Forklift openings must run lengthwise for unobstructed air plenum to the bulkhead.
- Dunnage of at least 100mm can be used instead of pallets. Provide unobstructed air passages lengthwise (door to bulkhead).
- 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 and avoid heat build-up in the center.
- Leave at least 200mm between the top of the cargo and ceiling for a chimney effect.
- Do not exceed the maximum permissible mass to prevent rejection at crane handling.
- Store all containers with ventilated cargo under cover with doors open. Ensure maximum fresh air circulation in storage to minimize condensation.
1.2.3 Cargo Protection
- Store loaded containers under cover while awaiting transport, with doors open and well-ventilated.
- Do not store loaded open door containers for more than four (4) days before vessel departure, to ensure the maximum storage period of 14 days (pre-shipment plus voyage) is not exceeded.
- Water must never enter the container. Close doors during rain or inclement weather; reopen when safe.
- Open door containers are only allowed under deck if PPECB is satisfied there is at least one complete fresh air change per hour and at least 90 air circulations per hour, based on the empty deck volume.
1.3 Handling of Refrigerated Containers Prior to Shipment
Containers can be loaded and kept at an inland depot or taken to a port terminal. The following recommendations apply to both:
1.3.1 Container Terminal Checks
- Recooling must commence immediately on arrival at the terminal, and TTT specifications must be applied.
- Verify requirements in transport documents (CTO and TPO).
- Check temperature set points and fresh air ventilation.
- Ensure the container is in good condition, with no external damage from transport.
- Cooling unit must operate within design parameters, without excessive noise or heat build-up.
- Check and record temperatures at least every four hours, correlating with CTO and TPD specifications.
- Call the authorized technician of the shipping line immediately for adjustments or repairs.
- Leave the container on cooling until pick-up for transport to the terminal or vessel.
1.3.2 Corrective Actions
Any deviation in cooling unit function or incorrect temperature/fresh air settings must be immediately reported to:
- Shipping line (for mechanical malfunction and setting correction)
- 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 (times/dates of arrival and departure, power supply and failures, temperature readings). These may be required for insurance. Communicate temperature and other information to PPECB for temperature management during the voyage (see Chapter 9, par 2). PPECB must reject containers not operating within parameters or handled outside specifications, and inform the cargo owner of discrepancies and corrective actions.
1.4 Handling of Ventilated Containers Prior to Shipment
Shipping perishables in ventilated containers is a compromise and not always optimal. The following actions minimize losses:
- Protect cargo from the elements at all times. Keep ventilated containers dry, in the shade, and stored to allow maximum fresh air circulation.
- Protect containers from chemical, rodent, and other pollution that may affect food safety.
- Do not store ventilated perishable products for more than four (4) days in the terminal before shipment.
- Remove and destroy or sell on the local market (if fit for human consumption) 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 and that cargo will be carried as required. These checks allow ship personnel to make final adjustments and repairs.
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 the PPECB reefer code definitions and apply the correct conditions.
- Verify container settings (temperature set point, delivery air temperature (DAT), 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 corrective steps in consultation with the grower and shipping line.
1.5.2 Controlled and Modified Atmosphere Containers
Controlled (CA) and modified (MA) containers have special controllers for internal gases. 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, based on empty deck volume.
- On-deck ventilated containers must be protected against 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, as hot air from the cooling unit may be blown into the ventilated cargo.
- Some ventilated containers have extraction fans, which must be connected to a suitable power supply.
2. Conventional Refrigerated Shipments
Conventional shipments from South Africa can be grouped into three main categories:
- 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. Procedures for refrigerated conventional shipments are discussed below.
2.1 Loading Plans
Loading of refrigerated decks must consider the products and carrying temperature regimes:
- 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 (see tables 8 and 9, Chapter 8).
- Products to be carried at different temperature regimes must be shipped separately (especially avocados, mangoes, plums).
2.2 Temperature Maintenance During Loading
2.2.1 Temperature Measurements
Temperature measuring instruments and methods are discussed in Chapter 2. Taking a single temperature is not useful, as product temperature is constantly changing. Take product temperatures as frequently as possible and in as many stages and positions as possible. At least 20% of the total load (one out of every ten pallets) must be checked and recorded during loading. This should include:
- Regular temperature checks of products in the cold store or pallets delivered to the quayside, especially those exposed to wind and sun (check fruit on the outside of the pallet).
- Temperature checks during loading into decks, including thermocouple wire checks of pallet core temperature and outside of pallets. Warm fruit on the outside becomes warm fruit in the middle once tightly stowed.
2.2.2 Temperature Increases
Record product temperatures and only load pallets within specified tolerances. Close hatches and start recooling as soon as the temperature of already stowed produce reaches or exceeds the tolerance. Product temperatures on the outside of pallets will increase during loading. Centers of pallets with produce packed in polyethylene bags should never be allowed to increase during loading. Centers of ventilated cartons (e.g., stone fruits, avocados, mangoes) may increase by a maximum of 3.0°C before cooling is recommenced (see PPECB product protocol and Chapter 8, par 3.4.2). Report all temperature deviations to PPECB for a temperature management procedure.
2.2.3 Crane Feeding Rates
Never delay pallets with cooled produce on the quayside. Cranes must be fed at the same rate as the loading rate. There should never be more pallets than can be handled by two crane swings. Return pallets to the cold store for recooling in case of equipment breakdown.
2.2.4 Recooling During Breaks
No pallets should be in air locks or on the quayside during tea and lunch breaks. Close decks and apply cooling during breaks longer than 30 minutes. High humidity in port areas (80–100% RH) causes rapid condensation on cold surfaces, leading to microbiological spoilage and carton collapse.
2.2.5 Protection of Cargo
Protect perishable cargo against the elements and pollution during and after loading. This applies to cargo on the quayside and produce already loaded into decks. Minimize exposure to sun and wind. Load decks quickly, close, and start cooling immediately. Avoid tainting by 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
Stowage into conventional decks requires organizational skills and knowledge. Key considerations:
2.3.1 Heat Leakage and Air Circulation
Some decks/positions are exposed to more heat leakage. Direct sufficient cold air circulation to these areas:
- Decks above heated bunker tanks
- Deck sides in contact with engine room bulkhead
- Deck areas in the narrow end of the bow
A vertical row of pallet bases stacked against the engine room bulkhead allows for additional vertical air circulation.
2.3.2 Loading Configuration and Air Circulation
Ensure adequate air circulation through the load and an unobstructed return air plenum (minimum height 150mm). Pallet height must not exceed 2.1m at loading to ensure efficient return air plenum. 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 pallet base openings of 2-way pallets face the air supply direction.
2.3.3 Damaged Pallets and Cartons
Remove and fix all broken pallets. Broken pallets destroy cargo and load stability, causing damage and affecting air circulation. 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 at all times. These records are required to trace all treatments and conditions the cargo was exposed to, for food safety and quality risk assessment.
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 specified carrying conditions are understood, set, and applied:
- Temperature set point and air delivery temperature as per carrying temperature specification (reefer code)
- Fresh air ventilation set to maintain CO₂ below 0.5%
- Controlled atmosphere conditions maintained as specified
- Record all temperatures and related information
- Inform PPECB of any deviation from the carrying condition specification
2.4.2 Recooling Times
Recooling of cargo spaces and cargo must start immediately after loading. Guidelines for reaching carrying conditions:
- Citrus fruit: all precooled – 12 hours; all non-precooled – 6 days
- Deciduous fruit: packed in polibags – 12 hours; not packed in polibags – 4 hours
- Frozen produce: maximum 3 hours
- Subtropical fruit: maximum 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. Cold treatment specifications are agreed bilaterally between the Departments of Agriculture of both exporting and importing countries. All cold treatments of citrus and deciduous fruit require a maximum treatment temperature of 0.0°C or colder for a minimum period of 12 days. The entire process must be supervised and certified by an independent organization (PPECB in South Africa).
3.1 Temperature Specifications
- Total load must be precooled to below -0.5°C prior to loading.
- Product temperature increases during handling/loading are limited to a maximum of +2°C.
- Treatment only starts when the specified product temperature is reached.
- Treatment is cancelled if product temperature increases above the requirement; treatment must restart.
- Some countries specify maximum air temperatures and defrost conditions.
3.2 Treatment Duration
Cold treatment period varies from a minimum of 12 days up to 22 days, depending on the insect. Some countries use a sliding temperature and time scale for small temperature increases (mainly during defrosting).
3.3 Temperature Recooling Requirements
- Product and air temperatures must be recorded continuously.
- Final approval is based on treatment temperature data.
- Use approved, accurately calibrated temperature measuring and recording devices.
- Install temperature sensors in specified positions.
3.4 Temperature Checks Prior to Sailing
Check all temperatures, recorders, and settings prior to sailing for last-minute adjustments and to prevent rejections by quarantine authorities.
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. PPECB can issue these as needed. Exporters are responsible for ensuring certificates are delivered to quarantine 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. Specific requirements for ventilated conventional shipments are as follows:
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. Fluctuations result in physiological and microbiological quality losses, which cannot be controlled during ventilated shipments.
- Preshipment, transshipment, and post-discharge conditions are unpredictable and uncontrollable, making informed decisions impossible. Lack of reliable information complicates dispute resolution.
4.2 Fresh Air Circulation
Continuous fresh air ventilation through the load is the only effective way to avoid condensation on the product and packaging. Air exchange rates of at least 90–120 complete fresh air changes per hour (based on empty deck volume) are required. However, humid marine air may deposit moisture directly 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 Aspects
- No chemical pollution is allowed. Perishable cargo must be stowed in completely separate spaces, with no contact with chemicals (including exhaust, bunker, and diesel fumes).
- No physical contamination is permissible (metal objects, glass, wood splinters, sand, dust). Decks must be absolutely clean before and during loading and the voyage.
- No microbiological contamination is allowed (no rodents, remains of previous cargo, or water intrusion).
4.4 Cargo Protection – Product Quality Aspects
- Never stow cargo near heat sources (heated bunker tanks, engine room bulkheads).
- Ensure adequate airflow through and around the load.
- Stabilize cargo to prevent movement during the voyage.
- Never handle cargo directly on the quayside surface. Protect cargo from the elements after discharge.
5. Shipping Information
All shipping information must be delivered to PPECB in the format and times specified in PPECB regulations. This is a statutory requirement; failure to comply may result in legal action against the shipping line, including refusal to load the vessel again in a South African port.
Information required by PPECB includes:
- Reefer lists for containerized shipments
- Stowage plans, including the reefer code for all conventional shipments
- Bills of lading within 5 days from departure