Cooler Vans for Cleaner Cities
Cooler Vans for Cleaner Cities
Background
Refrigerated vans are vital to keeping our food and medicines fresh, but traditional diesel-powered models contribute significantly to air pollution and carbon emissions in cities. As the UK moves towards net-zero, the cold chain logistics sector faces increasing pressure to find cleaner, more efficient alternatives that meet both environmental targets and commercial demands.
The Challenge
Reported by Mordor IntelligenceLink opens in a new window, the UK’s cold chain logistics market is worth over £9 billion as of 2025, with more than 250,000 refrigerated vehicles currently in operation, but only around 10% are low emission. Conventional diesel refrigeration vans emit high levels of nitrogen oxides and particulates, exceeding new EU emissions standards and conflicting with air quality and net-zero goals.
CoolVanLink opens in a new window, a leading UK manufacturer of refrigerated vehicles based in Lancashire, wanted to revolutionise the sector by developing a zero-emission, fully electric refrigerated van that could deliver reliable cooling performance without the environmental cost.
However, achieving this required advanced expertise in electrification and energy management, as well as access to specialist testing and simulation facilities, capabilities that CoolVan could not develop in-house. Innovate UK funding enabled the company to collaborate with Warwick Manufacturing Group (WMG) and GAH Refrigeration LtdLink opens in a new window, combining academic research, technical innovation, and industry experience to overcome these challenges and turn the concept into reality.
Solution
Funded by Innovate UK, the Cit-E-Van project brought together CoolVan, GAH Refrigeration Ltd, and WMG to design and demonstrate a next-generation electric refrigerated vehicle (ERV).
WMG’s Zero Emissions Transport Applications group provided expertise in electrification, energy management, and digital engineering, using advanced simulation and real-time testing platforms to accelerate the design process. The team modelled the vehicle’s thermal performance and optimised the cooling system using model-based predictive control, ensuring temperature stability while minimising energy use.
The project delivered several key innovations:
- A fully electric, zero-emission alternative to traditional diesel-powered refrigeration units.
- A highly thermally efficient and eco-friendly insulation system, replacing conventional designs that use non-recyclable polyurethane cores with glass-reinforced polyester skins.
- An advanced thermal energy management strategy to enable predictable and resilient temperature-energy control.
- Scalable technologies suitable for electric van conversions and adaptable to heavy-duty refrigerated vehicles.
Experiment showing benefit of using novel insulation panels. Cit-E-Van on left, conventional diesel design on right.
Together, these innovations produced an all-electric, zero-emission refrigeration system that combines sustainability, performance, and commercial practicality, helping to set a new standard for clean, efficient cold chain transport.
“At WMG, we specialise in applying digital engineering and sustainable transport research to real-world industrial challenges. Through advanced modelling, thermal analysis, advanced control and real-time testing, we were able to help CoolVan rapidly de-risk and optimise their electric refrigeration system. The Cit-E-Van project demonstrates how collaborative innovation can accelerate the shift towards cleaner, more efficient refrigerated vehicles that are commercially viable as well as environmentally transformative.”
- Truong Dinh, Associate Professor – Reader, Zero Emissions Transport Applications
Impact
86% lower carbon emissions, 35% less energy use, 32% lower running costs
The Cit-E-Van project proves that sustainable refrigerated transport can be achieved without compromising performance. Led by WMG’s Zero Emissions Transport Applications group, the initiative shows how electrification and digital engineering can deliver cleaner, more efficient logistics.
The electric system lifecycle significantly cuts emissions and noise pollution, helping cities meet air quality goals. With the global refrigerated road transport market growing rapidly, this technology is well placed for large-scale adoption and is driving the shift towards cleaner, quieter urban deliveries that benefit both businesses and the environment.
On average, the new ERV system achieves an 86% reduction in carbon emissions, a 35% cut in energy use, and a 32% drop in annual running costs compared to diesel models. Despite only a 4% higher upfront investment, it reaches breakeven in just two years, offering strong environmental and commercial value.
Building on this success, WMG and CoolVan continue to develop next-generation ERV technologies through Innovate UK and APC-funded projects, shaping the future of sustainable refrigerated transport in the UK and beyond.
"Working with WMG has been invaluable in helping us translate cutting-edge research into a commercially ready, zero-emission refrigeration system. Their expertise in energy management, simulation and thermal optimisation accelerated the development of our all-electric van and gave us the confidence that the system would deliver reliable performance in real-world conditions. This collaboration has enabled us to take a major step forward in offering cleaner, more sustainable refrigerated transport to our customers.”
— CoolVan
Contact wmgbusiness@warwick.ac.ukLink opens in a new window to explore how WMG can support your sustainable transport innovation.