TRT Converts Fonterra Tankers Into Tractor Units

OVERVIEW

TRT's Hamilton workshop is converting Fonterra's end-of-life tanker trucks into tractor units and rigid refrigeration bodies for the co-operative's packaged product fleet. The programme keeps well-built trucks in service on lighter duties instead of retiring them outright.

1.4 million km

Typical distance before a tanker truck is retired

10 units a year

Planned conversion rate, about 5% of the fleet

700mm

Chassis shortened per truck

400 hours

Work involved in each conversion

SITUATION

Fonterra retires its milk tanker trucks once they reach around 1.4 million kilometres. The trucks are well maintained and built to a high specification, so Fonterra wanted more value from them before they left the fleet.

Rather than retire the trucks outright, Fonterra chose to give them a second life on lighter duties. The converted units tow 16.5m refrigerated trailers built by Freuhauf, taking on distribution of packaged product.

CHALLENGE

Converting an 8x4 tanker chassis into a tractor unit meant more than a respray and reflag. The chassis needed shortening and the rear axles moved forward, to get the right weight distribution on the steer axles once fully loaded.

Every ancillary on the chassis, including the diesel, hydraulic, and Adblue tanks, needed relocating to suit. The finished units also had to meet supermarket site rules, which do not allow overhead exhaust stacks.

SOLUTION

TRT's Fabrication Foreman Wayne Bryant designed the conversion. He worked closely with Fonterra's Milk Distribution operations team and the trailer suppliers to finalise a configuration suited to metro-type operation.

Each 8x4 chassis is shortened by 700mm from the end, with the rear axles moved forward rather than cutting a section from the middle. Axle, suspension, and fifth wheel positions are set from weighed axle loads at full load.

The diesel and hydraulic tank unit and the Adblue tank are relocated to suit the new configuration. Driveshafts are shortened and balanced in TRT's own driveshaft workshop.

The rear exhaust stack is replaced with a side-mounted exhaust exiting on the driver's side, to meet supermarket site requirements. Each conversion takes around 400 hours, with TRT's Te Rapa workshop running two trucks through at a time.

Five Volvo Version 4 trucks are being converted into tractor units, with another five fitted with rigid refrigeration bodies. "We plan to average 300k km out the converted units," says Lamine Abderrahim, Fonterra's Value Chain Transformation Manager.

MADE POSSIBLE:

Nine 8x4 and one 6x4 2014 model trucks are currently going through conversion at TRT's Te Rapa workshop. A further batch of 2017 model trucks is due in during May and June.

Fonterra plans to convert around 10 units a year, about 5% of the relevant fleet, as more tanker trucks reach the end of their milk collection life. Converted units will progressively replace leased tractor trucks in the refrigerated transport fleet.

The programme is in its first year, and Fonterra is assessing how the converted units perform in the milk delivery fleet over the months ahead.