With truck and driver shortages wreaking havoc on their supply chains, some companies find themselves contemplating what was once unthinkable: starting their own fleets.
Peter Bradley is an award-winning career journalist with more than three decades of experience in both newspapers and national business magazines. His credentials include seven years as the transportation and supply chain editor at Purchasing Magazine and six years as the chief editor of Logistics Management.
It wasn't too many years ago that private fleets seemed to be under siege: In the corner office, they were often viewed as a burden on the balance sheet and a cost center whose operations were completely tangential to the company's core mission. But private fleets have proven resilient, and as for-hire carriage gets more expensive and trucks get harder to find, they seem to be making a comeback. Private fleets may not be cheap to run, but they do offer substantial benefits for some businesses—particularly those with predictable routings, the potential for backhauls, and prickly customers who won't tolerate late or missed deliveries.
It's not that private or dedicated fleet managers are exempt from the problems that plague common carriers—a dwindling supply of drivers, hours of service regulations, astronomical fuel costs (60 cents a gallon over year-earlier costs in mid-June), and so on. But the DC manager who knows he controls his trucks may just sleep a little better at night.
Given the climate, it's probably no surprise that observers are reporting a resurgence of private fleet operations. Gary Petty, president and CEO of the National Private Truck Council (NPTC), a trade group whose members operate and manage private fleets for U.S. businesses, reports that most of his group's members (who represent about 500 private fleets) are expanding or plan to expand their private fleet capacity. In many cases, he says, they're using their fleets to generate cash, selling unused fleet capacity on the open market. At the same time, he reports, some businesses that had given up their private fleets are beginning to explore reviving their fleets.
Desperately seeking trucks
Petty sees several reasons for the revival of interest in the private fleet option. "It's increasingly difficult to get capacity that meets [customers'] delivery expectations," he says. "It's often hard to get at any price. And in cases where you can get it, the price is going up dramatically. Price is in the hands of the carriers. They can pick and choose their customers. That puts the manufacturer or the distributor or the retailer in the unenviable position of being at the mercy of the market."
As a corollary, Petty says some businesses are seeing captive capacity as a component of shareholder value—not only as an assured means of moving freight, but as a valuable marketing tool via the advertising on the sides of the trucks. "That sends a powerful message as well as meeting the transportation needs of the company," he says.
Though he acknowledges that private fleets face the same difficulties finding and retaining drivers that bedevil their for-hire counterparts, Petty believes that private fleets enjoy a few advantages. "The pay is usually better in private fleets," he says, "and working conditions are better. Institutionalized care and feeding programs make private fleets more favorable than others." As evidence of that, Petty points to the results of a survey conducted by NPTC of 200 companies with private fleets. The survey results showed annual driver turnover in the range of 11 to 16 percent—far better than truckload carriers, many of which have turnover rates of 100 percent or higher each year.
Total dedication
Executives whose companies manage dedicated fleets for their customers agree that the capacity shortage is motivating companies to reconsider the private and dedicated options. Gordon Hale, vice president of dedicated operations for Schneider National Inc., says that over the last 15 months, he's seen an explosion of demand for dedicated contract carriage, in which a customer contracts with a third party for exclusive use of fleet drivers and equipment. "People want to lock up capacity," he says, "particularly after the surge of '04. They want to tie up capacity before the surge of '05.
"The second thing I've seen is private fleet owners struggling to find drivers, and they're seeking folks like us to help supplement the fleet," says Hale. "That's driven by the driver shortage." The driver issue affects dedicated carriers, too, of course, although Hale says that for Schneider, finding drivers for those fleets has been an issue only in some regions, like the Northeast and Midwest.
Hale adds that he believes some businesses are turning to companies like Schneider because they want providers that can offer not only trucking, but also the ability to integrate with intermodal, third-party and one-way fleets. He cites the example of one customer with a DC-to-retail operation that needs 10 trucks on Mondays, five each day Tuesday through Thursday, 15 on Friday, and 10 on Saturday. "In the old days, we would size that to a 10-truck fleet. Drivers would sit idle Tuesday to Thursday and some of the Friday freight would be delayed. Now, we can meet the requirement with a baseline of five trucks dedicated. We take the next piece of the surge with a third party, saying we need five trucks on Monday, Friday, and Saturday, giving them three days' worth of freight. For the extra five on Friday, we can cover that with our one-way drivers."
David Bouchard, senior vice president of U.S. supply chain for high-tech and consumer products for Ryder, has also seen an upsurge in the dedicated-fleet business. "We have seen more activity this past year than we've seen in the past several years," he says. "I agree that the capacity situation in the overall market is a factor."
But Bouchard thinks there's more to it than just shippers looking for ways to get around the capacity crunch. "At the end of the day in my mind, a prospect decides on a dedicated operation for service reasons. We see opportunities for companies that have not had dedicated in the past or are looking to make changes in modes or providers. ... Where there can be an engineered solution and improvement in the system to reduce total cost, that's where we see an opportunity."
Like Hale, Bouchard believes customers looking at dedicated carriage see it as part of a bigger picture. "The approach Ryder tries to take is not to focus on the dedicated carriage solution, but to examine movement of product. We try to assess that and come up with the best combination of services to meet the customer's service and cost needs. That's usually an integrated solution."
Like nearly everyone close to the trucking industry, he sees the driver shortage as a serious issue. That includes the private and dedicated sectors of the business. "When families sit around the table, I'm not sure that a lot of them are encouraging their kids to pursue truck driving as a career," he says. "The market should do more to recognize the importance of the driver."
Bouchard echoes Petty's opinion that dedicated and private fleets have advantages over common carriers. "One of the benefits for dedicated is that we make efforts to factor in quality of life into our designs. Being able to be home creates value to [drivers] and their families." That, he says, leads to employees who are more attentive to the service requirements of customers. "A lot of benefits accrue from it."
No shortage of problems
Of course, the driver shortage is by no means the only issue plaguing the trucking industry. Exacerbating the driver shortage are the hours of service rules that took effect at the beginning of last year. Those rules placed new limits on driver work hours, forcing changes in carrier, shipping and receiving operations around the nation. A court challenge has left the fate of those rules uncertain. Right now, they're back in the hands of the Federal Motor Carrier Safety Administration, although Congress may step in and impose the disputed rules.
Petty says that his members generally support the rules, and in some cases, have found them to be unexpectedly favorable. "What we didn't expect that has happened is cooperation and a willingness to find a middle ground for getting access to DCs," he says. "People are realizing that under hours of service, there's really an incentive to ... get in and out and optimize the allowable drive time," he says. "I think the argument can be made, although not in all cases, that there are more opportunities for productivity [improvements] under the new rules. I just hope we don't go back to the drawing board."
Hale agrees that the rules have had a big impact on truckers' operations. "Hours of service have definitely changed the way we operate," he admits. "We have to go to the marketplace to cover that cost. It takes a lot of communication to help customers understand those costs."
Rising fuel costs have also spurred private fleets to focus on ways to boost productivity. In mid-June, nationwide diesel costs averaged $2.31 a gallon, more than 61 cents above year-earlier levels, and with oil selling at close to $60 a barrel, there's no relief in sight.
Those skyrocketing fuel prices, Petty says, have led to redoubled efforts to improve fuel economy. "Companies are putting in incentives to ensure that drivers are operating in the most efficient way possible," he says. He notes that the NPTC has launched online fuel economy workshops, sponsored by Cummins Engine, on its Web site.
Other efforts to control costs involve expanding use of on-board technology, Petty says. The goal, he adds, is more than capturing operational data to improve efficiency; the monitoring tools also enable fleet managers to measure their costs against the market. That's especially valuable, Petty says, if the fleet is operating as a profit center. "There's not a lot a trucking company can do about the cost of fuel or insurance, but they can do a lot to mitigate the unnecessary costs that flow from not paying attention to things." One example: he cites a study by the Federal Motor Carrier Safety Administration that showed that tires 2 percent under the correct pressure can add $500 to operating costs through wear and tear and reduced fuel economy.
Heading for a meltdown?
Though private and dedicated fleets may be finding conditions more favorable than they've been in years, that's not to say they foresee a rosy future. They still face severe challenges, as does the entire U.S. transportation network.
Petty is worried that unless industry and policy-makers address many of the issues facing the network and do it soon, the nation could face a transportation meltdown of sorts. "When you look at the long-term perspective, what the volume of freight is going be, and the pressure on the infrastructure in the next 20 years," he says, "you realize we're ... hitting the wall, where with a lack of drivers and the increased demand for goods, we're going to have a logistics crisis. Add to that the huge congestion getting in and out of major markets—especially with some communities not improving access, but figuring ways to restrict access—and there is a time bomb ticking."
Fruit company McDougall & Sons is running a tighter ship these days, thanks to an automated material handling solution from systems integrator RH Brown, now a Bastian Solutions company.
McDougall is a fourth-generation, family-run business based in Wenatchee, Washington, that grows, processes, and distributes cherries, apples, and pears. Company leaders were facing a host of challenges during cherry season, so they turned to the integrator for a solution. As for what problems they were looking to solve with the project, the McDougall leaders had several specific goals in mind: They wanted to increase cherry processing rates, better manage capacity during peak times, balance production between two cherry lines, and improve the accuracy and speed of data collection and reporting on the processed cherries.
RH Brown/Bastian responded with a combination of hardware and software that is delivering on all fronts: The new system handles cartons twice as fast as McDougall’s previous system, with less need for manual labor and with greater accuracy. On top of that, the system’s warehouse control software (WCS) provides precise, efficient management of production lines as well as real-time insights, data analytics, and product traceability.
MAKING THE SWITCH
Cherry producers are faced with a short time window for processing the fruit: Once cherries are ripe, they have to be harvested and processed quickly. McDougall & Sons responds to this tight schedule by running two 10-hour shifts, seven days a week, for about 60 days nonstop during the season. Adding complexity, the fruit industry is shifting away from bulk cartons to smaller consumer packaging, such as small bags and clamshell containers. This has placed a heavier burden on the manual labor required for processing.
Committed to making its machinery and technology run efficiently, McDougall’s leaders decided they needed to replace the company’s simple motorized chain system with an automated material handling system that would speed and streamline its cherry processing operations. With that in mind, RH Brown/Bastian developed a solution that incorporates three key capabilities:
Advanced automation that streamlines carton movement, reducing manual labor. The system includes a combination of conveyors, switches, controls, in-line scales, and barcode imagers.
A WCS that allows the company to manage production lines precisely and efficiently, with real-time insights into processing operations.
Data and analytics capabilities that provide insight into the production process and allow quick decision-making.
BEARING FRUIT
The results of the project speak for themselves: The new system is moving cartons at twice the speed of the previous system, with 99.9% accuracy, according to both RH Brown/Bastian and McDougall & Sons.
But the transformational benefits didn’t end there. The companies also cite a 130% increase in throughput, along with the ability to process an average of 100 cases per minute on each production line.
Artificial intelligence (AI) and the economy were hot topics on the opening day of SMC3 Jump Start 25, a less-than-truckload (LTL)-focused supply chain event taking place in Atlanta this week. The three-day event kicked off Monday morning to record attendance, with more than 700 people registered, according to conference planners.
The event opened with a keynote presentation from AI futurist Zack Kass, former head of go to market for OpenAI. He talked about the evolution of AI as well as real-world applications of the technology, furthering his mission to demystify AI and make it accessible and understandable to people everywhere. Kass is a speaker and consultant who works with businesses and governments around the world.
The opening day also featured a slate of economic presentations, including a global economic outlook from Dr. Jeff Rosensweig, director of the John Robson Program for Business, Public Policy, and Government at Emory University, and a “State of LTL” report from economist Keith Prather, managing director of Armada Corporate Intelligence. Both speakers pointed to a strong economy as 2025 gets underway, emphasizing overall economic optimism and strong momentum in LTL markets.
Other highlights included interviews with industry leaders Chris Jamroz and Rick DiMaio. Jamroz is executive chairman of the board and CEO of Roadrunner Transportation Systems, and DiMaio is executive vice president of supply chain for Ace Hardware.
Jump Start 25 runs through Wednesday, January 29, at the Renaissance Atlanta Waverly Hotel & Convention Center.
A lithium refinery that broke ground this week on construction of a $1.2 billion plant in Oklahoma will soon become one of the nation’s largest factories for producing materials for batteries, according to officials with Connecticut-based Stardust Power Inc.
In December 2024, the company said it had acquired the 66-acre site for the refinery in Muskogee, Oklahoma, as well as the right of first refusal for future expansion on an adjacent 40-acre parcel of land. In choosing those plots, it cited the location’s proximity to the country’s largest inland waterway system, robust road and rail networks, and a skilled workforce rooted in the oil and gas sector.
Up next, the project will be developed in two phases, with the first phase focused on constructing a production line capable of producing up to 25,000 metric tons per annum. The second phase will add a second production line, bringing the total capacity to 50,000 metric tons per annum.
As it moves into the construction stage of the project, the company said it would follow sustainable standards, including responsible corporate practices, climate action, and the energy transition. “Our lithium refinery will be crucial for addressing U.S. national security and supply chain risks. By onshoring critical mineral manufacturing, we are helping to sustain America’s energy leadership,” Stardust Power Founder and CEO, Roshan Pujari, said in a release. “At a time when foreign entities of concern are attempting to consolidate critical minerals, Stardust Power is proud to play a key role in safeguarding American interests and supporting Oklahoma’s local economy,” Pujari said.
Local officials cheered the project for the hundreds of jobs it is projected to create once fully operational, and for its role in helping strengthen the U.S. supply chain for critical minerals by reducing the nation’s reliance on China for the production of critical rare earth elements.
The new cranes are part of the latest upgrades to the Port of Savannah’s Ocean Terminal, which is currently in a renovation phase, although freight operations have continued throughout the work. Another one of those upgrades is a $29 million exit ramp running from the terminal directly to local highways, allowing trucks direct highway transit to Atlanta without any traffic lights until entering Atlanta. The ramp project is 60% complete and is designed with the local community in mind to keep container trucks off local neighborhood roads.
"The completion of this project in 2028 will enable Ocean Terminal to accommodate the largest vessels serving the U.S. East Coast," Ed McCarthy, Chief Operating Officer of Georgia Ports, said in a release. "Our goal is to ensure customers have the future berth capacity for their larger vessels’ first port of calls with the fastest U.S. inland connectivity to compete in world markets."
"We want our ocean carrier customers to see us as the port they can bring their ships and make up valuable time in their sailing schedule using our big ship berths. Our crane productivity and 24-hour rail transit to inland markets is industry-leading," Susan Gardner, Vice President of Operations at Georgia Ports, said.
It appears to have found that buyer in Aptean, a deep-pocketed firm that is backed by the private equity firms TA Associates, Insight Partners, Charlesbank Capital Partners, and Clearlake Capital Group.
Through the purchase, Aptean will gain Logility’s customer catalog of over 500 clients in 80 countries, spanning the consumer durable goods, apparel/accessories, food and beverage, industrial manufacturing, fast moving consumer goods, wholesale distribution, and chemicals verticals.
Aptean will also now own the firm’s technology, which Logility says includes demand planning, inventory and supply optimization, manufacturing operations, network design, and vendor and sourcing management.
“Logility possesses years of experience helping global organizations design, build, and manage their supply chains” Aptean CEO TVN Reddy said in a release. “The Logility platform delivers a mission-critical suite of AI-powered supply chain planning solutions designed to address even the most complex requirements. We look forward to welcoming Logility’s loyal customers and experienced team to Aptean.”