How AEM Reduced Shore Power and Boosted eTRU Performance with Merlin Solar
- Merlin Solar Team
- Nov 10
- 2 min read
Transitioning to Cleaner, More Efficient Refrigeration
Traditional diesel TRUs contribute significantly to greenhouse gas emissions and rely heavily on fossil fuels. While electric TRUs (eTRUs) provide a cleaner alternative, performance often drops in real-world conditions. Without shore power or oversized batteries, eTRUs can struggle to operate efficiently, with some consuming up to 200 kWh per day.
AEM sought a proven solution to enable reliable, zero-emission operations for long-haul refrigerated trailers under demanding temperature conditions.
The Challenge
eTRUs are often limited by battery capacity and lack of shore power availability, which can lead to:
Reduced operating range for long-haul deliveries
High energy consumption and costs
Increased maintenance and downtime
AEM needed a solution that would extend range, minimize shore power dependency, and maintain performance in extreme temperatures.
The Solution
To overcome these limitations, AEM deployed 5.6 kW of Merlin solar panels paired with a 100 kWh LFP battery on a 48-ft trailer equipped with their 46V DC zero-emission TRU.
The system provided continuous power even in extreme conditions:
-20°F operation for multi-temp refrigerated loads
Daily 12-hour multi-temp routes at -10/35°F in 88°F ambient heat
Frequent door openings without significant battery drain
Merlin’s solar integration reduced shore power demand, extended operational range, and enabled reliable, zero-emission operation for long-haul fleets.
Proven Results
Shore Power Reduction:Â Shore power demand dropped to 48 kWh/day, down from ~200 kWh/day.
Extended Range: Enabled a 2,000+ mile trip from Miami to Phoenix on a single shore power charge.
Operational Reliability: Achieved 130,000+ hours of zero-emission operation across fleets.
Daily Efficiency:Â System consumed only 8.2 kWh/day, with eTRUs completing full-day routes using just 50% of battery capacity, even with frequent door openings.
Minimal Maintenance:Â Near-zero downtime, improved range, and extended component life.
The Outcome
By integrating Merlin’s rugged, flexible solar panels and LFP battery technology, AEM achieved reliable, zero-emission refrigeration, reduced energy costs, and minimized shore power dependence.
Key results include:
2,500 gallons of diesel saved per trailer per year
50 tons of GHG reductions per trailer per year
Shore power demand reduced to 48 kWh/day from 200 kWh/day
$3,248 estimated annual savings per trailer compared to diesel TRUs
This project demonstrates how practical, innovative solar technology delivers measurable results, supporting sustainable, long-haul refrigerated operations.