Shippers looking to crack down on cargo theft are enlisting the aid of high-tech devices. But there's more to it than simply tucking a covert wireless tracker into a shipment.
Mark Solomon joined DC VELOCITY as senior editor in August 2008, and was promoted to his current position on January 1, 2015. He has spent more than 30 years in the transportation, logistics and supply chain management fields as a journalist and public relations professional. From 1989 to 1994, he worked in Washington as a reporter for the Journal of Commerce, covering the aviation and trucking industries, the Department of Transportation, Congress and the U.S. Supreme Court. Prior to that, he worked for Traffic World for seven years in a similar role. From 1994 to 2008, Mr. Solomon ran Media-Based Solutions, a public relations firm based in Atlanta. He graduated in 1978 with a B.A. in journalism from The American University in Washington, D.C.
As beta tests go, it wasn't much of a sampling. The three-month trial involved only 10 trucks used by FedEx Corp.'s Custom Critical "White Glove" unit, which transports time-sensitive, high-value goods requiring some form of special handling. But what emerged could tilt the playing field, albeit modestly, in favor of those tasked with securing their supply chains from villains, thieves, and scoundrels.
The White Glove unit was testing cellphone technology that would enable an employee to remotely disable a stolen or hijacked vehicle once it got back on the road. With the truck immobilized, the goods inside could be quickly recovered and the thieves apprehended because they couldn't stray far enough to elude law enforcement.
Carl Kiser, operations manager for the White Glove service, was impressed with the performance. "The technology worked," he says.
It is unclear how the new tool would be incorporated into Custom Critical's 1,400-truck fleet. The division already outfits about 20 percent of its trucks with devices affixed to dashboards and embedded in driver key fobs to automatically disable the truck unless the driver enters a special code to start up the engine. All of Custom Critical's fleet is equipped with global positioning system (GPS) technology that has become a mainstream tool to combat theft on the roads.
The ability to stop a stolen conveyance from a distance could become the latest weapon in the cargo theft wars, which cost American industry an estimated $6 billion to $20 billion annually in the value of goods pilfered while in transit. (Those estimates exclude the value of goods stolen from warehouses and distribution centers.) Firm figures aren't expected to be available until early next decade when the FBI rolls out a long-planned database dedicated to tracking cargo theft. Currently, the bureau consolidates cargo theft data with statistics covering other types of crime.
"Harden" the target
The effectiveness of anti-theft technology is in the eye of the beholder. IT vendors believe their tools can make great strides in combating theft and pilferage. Others are not so sure. Barry Brandman, president of Danbee Investigations, a consulting firm in Midland Park, N.J., that has worked in the supply chain security field since the mid-1970s, says technology, in and of itself, has limited value. Much of it doesn't work as promised or is quickly figured out by today's sophisticated criminal element, he says.
"These are businesspeople who are often part of organized crime groups that have their own supply chains," he says. Cargo thieves are so adept at swiftly spiriting their booty away from crime scenes that most property stolen out of supply chains is never recovered. Often, the goods end up in foreign countries.
"It generally takes less than four hours for stolen cargo to leave the state where the theft occurred, and everything from scheduling the hit and negotiating the sale price of the goods to the choice of export conveyance has already been arranged," says Brandman.
Arthur Arway, security director of the Americas for DHL Global Forwarding, the world's biggest airfreight forwarder, says anti-theft technology is most effective when it "hardens the target" by blanketing all channels through which thieves might try to infiltrate the supply chain. The idea, says Arway, is to create enough uncertainty in the minds of thieves so "they will avoid you and go after someone else."
Several vendors in the cargo security market have already begun offering some type of multilayered security program. For example, Safefreight Technology, an Edmonton, Alberta-based IT provider, uses its "SmartFleet" application to attack in-transit theft at multiple levels. Safefreight first asks clients to define "security zones" where trailer doors are scheduled to be opened. It then affixes sensors to the equipment that alert the user in real time if a door has been opened outside any pre-established zone, whether it be a small area such as a trailer yard or a large territory such as a multi-state region. Earl Bourque, Safefreight's chief technology officer, says most in-transit cargo theft occurs in confined spaces like loading docks.
The company's technology also tracks trailer schedules based on electronic interfaces provided to its customers. After the customer enters and submits the scheduling information, Safefreight uses its automated tracking system to monitor the driver, rig, and equipment in transit.
The SmartFleet system gives Safefreight customers a complete and accurate picture of their assets' location at all times, says Bourque. This helps reduce the potential for in-transit theft because the fleet is being constantly monitored and customers are notified in real time of any variances from preset conditions for routes, geographic zones, schedules, or door sensors. In addition, regular reports enable fleet managers to have a deeper and more accurate read of how effectively their equipment is being utilized, Bourque says.
"The goal of our systems is to take the technology beyond simple GPS tracking. We want to relieve fleet managers of the burden of continuously monitoring their fleets and enable them to optimize the security, safety, and efficiency of their assets," Bourque says.
Inside jobs?
Many shippers and anti-theft experts consider the driver to be the weak link in the security chain. For that reason, some anti-theft specialists have chosen to combat the problem with services and technology aimed at ensuring that carriers and their drivers follow pre-set procedures that minimize risk to their trailers and their loads.
As for how they monitor compliance, one method is to plant high-tech tracking devices inside loads. For example, FreightWatch International (USA), a global company that provides security services, makes use of a covert mobile wireless device manufactured by a Canadian company called Sendum Corp. The device, about the size of a folded-over cellphone, is used mostly to track truckload shipments of high-value goods such as pharmaceuticals and electronics. A vehicle with 24 pallets, for example, might be monitored by two or three of the embedded devices. The devices are inserted covertly, work off a satellite network, and will emit tracking signals at intervals that are pre-set by the user but which can be changed at any time. Generally, shippers or intermediaries embed the devices before the goods are packed. For the most part, trucking companies and their drivers are oblivious to their presence.
The devices will notify the user if the driver is not following pre-determined routes or established practices. The user then contacts the trucker who, in turn, relays the information to the driver. The reusable devices sell for $300 to $500 apiece, which doesn't include an ongoing subscription fee.
The process strengthens trucker and driver compliance, thus reducing the potential for an incident, says Ed Petow, director of quality control for Freightwatch (USA). "If you get compliance, there's less of a chance for theft," he says. Plus the prospect of surveillance tends to keep people honest. "I had one customer tell me that 'the trucking companies can't lie to me anymore,'" says Petow.
A role for RFID?
Even RFID is getting into the act. Mikoh Corp. of McLean, Va., has built and patented technology designed not to protect the asset while in motion, but the RFID chip tracking it. The chip automatically self destructs if removed from its original location, making it impossible for thieves to detach it and affix it to another item.
Mikoh officials acknowledge their company's technology will not directly prevent the theft or pilferage of an intransit shipment. They say, however, that once the RFID reader detects a security breach, users can take remedial action that may prevent future incidents. The company has also developed an advanced tag that leaves a smoke-like trace to indicate possible tampering, while the tag itself continues to function normally.
Mikoh's technology hit the market in September 2005 and today is used mostly by government agencies and onboard courier firms whose couriers carry time-sensitive and high-value material in briefcases. Perhaps the product's most widespread use is in Bermuda, where it's used to discourage tampering with the RFID chips used to ensure that commercial and personal vehicles are properly registered.
The RFID protection technology has gained little traction among large commercial users since its introduction. The lack of commercial customer uptake reinforces the perception that the cost of RFID tags and the expense and difficulty of implementation make it of doubtful value when it comes to fighting cargo crime.
Andrew Strauch, vice president, product management and marketing, says Mikoh is currently in the "educational" phase with commercial prospects. He reports that Mikoh is aggressively courting the pharmaceutical and healthcare industries, which he calls ideal candidates for technology to protect RFID tags because they make and ship high-value, perishable goods that are vulnerable to theft and tampering.
Strauch acknowledged his company's efforts have been hindered by the marketplace's lack of focus on protecting the RFID tags themselves. "RFID security has not been ignored," he says. "But users have been too busy figuring out the technology's economics and its effect on business processes to concentrate on the security of the tag itself." Mikoh's mantra, as expressed by Strauch, is "protect the tag, and you protect the asset."
Not the be-all, end-all
As with virtually all business applications, anti-theft technology cannot work effectively in a vacuum. Few dispute that the tools are less expensive, more user-friendly, and more robust than ever. However, experts warn against buying into the notion that IT offers the "silver bullet" premise that can solve what is a nagging and growing problem.
Brandman, a 36-year industry veteran, says anti-theft technology can only be effective when integrated into an organization's best practices. The growth in supply chain scope and complexity, the rise in the number of human touch points, and the fact that employees are involved, knowingly or not, in most thefts of mobile cargo combine to make the integration of technology and processes a requirement for a successful anti-theft program, he says.
"Technology must always be supported by appropriate policies, procedures, and trained personnel," Brandman says. Absent this holistic effort, "most end users will not know what they are buying," he adds.
Or as Jeanne Dumas, director of the Security Council for the American Trucking Associations, says, "Technology definitely has its place. But the best theft deterrent is common sense."
it's the intelligence, stupid!
Technology's most meaningful contribution to the science of supply chain security may lie not in its ability to stop today's thefts but in its capacity to prevent tomorrow's. By mining data from previous incidents, company executives, security consultants, and law enforcement authorities can spot behavioral patterns that are more than coincidental. With the past as prologue, networks, processes, and technologies can then be tweaked to deter tomorrow's thieves.
The Florida Highway Patrol, which in 2005 launched a Web-based system to notify law enforcement and multiple state agencies of every cargo theft within two minutes after the incident was reported, added in 2007 an online mapping program that tracks theft histories by county.
A recent query into activity in Osceola County, south of Orlando, found that 11 cargo thefts had occurred during a six-month period, which, based on historical data, was determined to be a high incident rate. Armed with the data, the Highway Patrol's Cargo Theft Task Force planted decoy tractor-trailers at a specific location in the county to lure and trap suspected criminals. The bait worked: Within days, thieves hit the site, stealing one decoy trailer and five decoy tractors. The stolen decoy trailer was followed to the Miami area, where the thieves were captured and arrested.
The IT tools are having a beneficial effect, says Lt. William Jackson, who coordinates the Task Force and administers the theft notification application, known as the "Electronic Freight Theft Management System." From 2002 to 2007, the number of annual reported cargo thefts in Florida dropped by 31 percent, according to Highway Patrol data.
Furthermore, as word gets out about the agency's technological prowess, criminals are shifting their focus to other states, according to Jackson. As a result, the state, long a prime destination for stolen goods because of its proximity to Central and South America and the Caribbean, could see a long-lasting reduction in cargo theft, he says. "Thieves are leaving Florida," he claims.
Meal kit producer HelloFresh relies on automation to guarantee fresh and accurate shipments to customers—and that reliance has only increased as the company has grown from a small German startup to a global enterprise serving consumers in 18 countries. Surging demand, expanding menus, and the ever-present challenge of meeting high food quality and safety standards add complexity to the HelloFresh model, necessitating a focus on technologies that can give the business an edge as it grows.
Zeroing in on the U.S. market, company leaders took a leap nearly five years ago that would help HelloFresh meet burgeoning local demand and set the stage for further expansion of its menu and capabilities. They added a brand-new distribution center (DC) in Irving, Texas, that would feature the most advanced technology in the company's North American fulfillment network to date.
"Once we had identified that we were moving toward a greenfield site, we saw the opportunity to have an enhanced fulfillment system in the building," Kyle DeGroot, vice president of operations engineering and technology for HelloFresh, says of the Irving project. "We wanted the capability to expand our product offering while maintaining or increasing efficiency from a fulfillment standpoint."
The answer to that challenge: an automated storage and retrieval system (AS/RS) from AutoStore. The system is now the centerpiece of a customized, high-tech fulfillment process that is speeding operations, increasing throughput, and improving productivity—all while giving HelloFresh the flexibility to shift and expand its menu without complicating the fulfillment process.
TAMING COMPLEXITY
HelloFresh was founded in 2011 in Berlin and has grown from its early days as a community-based business into a global organization that delivered more than 1 billion meals to customers in 2023, according to company data. Faced with escalating demand in the U.S., HelloFresh set out to expand its fulfillment network in 2020, adding the 377,000-square-foot Irving facility and bringing the company's U.S. fulfillment network to a total of eight DCs.
More than that, the Irving DC was an opportunity to advance the company's use of automated warehouse technology and build on its presence in the Dallas-Fort Worth metropolitan area—both because of the facility's size and because it was a greenfield site, offering a blank slate for innovation. The goal was to leverage the reliability, density, and speed of AutoStore as the heart of an automated meal kit assembly process, according to HelloFresh and leaders at Swisslog, the material handling automation specialist that designed and installed the AutoStore system.
For Swisslog, the project represented a departure from typical AS/RS installations, which are designed to handle traditional distribution center operations, including e-commerce and store fulfillment.
"HelloFresh is in the distribution business, shipping meals to the home. However, once we took a closer look at [the business], we [realized] that it acted more like a production operation," explains Colman Roche, vice president of AutoStore solutions for Swisslog Americas. "Items are moving in and out faster than in a typical system."
That's because HelloFresh orders need to be filled quickly and under precise conditions to meet food freshness and safety standards. And there are a lot of moving parts: HelloFresh subscribers can customize their meal plans from more than 100 weekly menu and market item offerings and choose the day of the week they want orders delivered. The company sources meal ingredients to minimize the time between receipt and shipping, and carefully packages components to ensure freshness and simplify preparation.
The meal kits themselves may include fresh produce, starches, seasonings, recipe cards, and nutritional information along with proteins—such as fish, chicken, and beef. Subscribers can also supplement their meals with snacks, desserts, and other items from the HelloFresh Market. As a result, a typical HelloFresh outbound container includes 16 items, which must be packed in a prescribed sequence. The entire process is conducted in a chilled environment that is maintained at 33 degrees Fahrenheit.
"That insight [into the nature of HelloFresh's operations] allowed us to take a different look at the system design and come up with something that flowed more easily [in a production environment]," Roche explains.
PUTTING THE SYSTEM TO WORK
HelloFresh uses varying levels of automation at its facilities around the world, but the AutoStore system in Irving is by far the most advanced, according to DeGroot, who describes the project as a unique application of the technology. Unlike typical installations—in which orders are initiated within the AutoStore and work their way through the fulfillment process via picking stations, pack out, and eventually to shipping—orders begin outside the AutoStore, in a manual pick zone. Orders are then inducted into the AutoStore via conveyor in a sequence that maximizes throughput and worker productivity.
Roche and DeGroot describe the process as follows: Orders are initiated in a manual pick zone, where box assembly begins with proteins and ice packs. Boxed orders are then transported by conveyor and inducted into the AutoStore in a controlled sequence and dynamically grouped in batches of four based on commonalities across the orders.
The partial orders are then delivered to pickers working at carousel ports, along with bins of ingredients from the AutoStore inventory that are needed to complete the order—this allows workers to pick directly into cartons at the AutoStore ports. Workers can fulfill four orders simultaneously, maximizing the number of picks they make from each bin. Inventory is replenished through the system's 11 induction ports to maintain freshness.
Downstream from the AutoStore, orders are conveyed to automated carton sealers and labeling equipment, and then sorted for shipping.
Swisslog's SynQ warehouse execution system (WES) manages the entire process—including routing, picking across all zones, replenishment, sortation, and label printing. SynQ also provides centralized inventory management and visibility based on a first-expired, first-out (FEFO) strategy that helps ensure freshness. The WES is integrated with the facility's warehouse management system (WMS) as well.
"[SynQ] is the brain behind everything, bringing it all together," says DeGroot.
Getting the system up and running was no small accomplishment, given its size and scale. The cube-based AS/RS takes up 100,000 square feet of the facility's total 377,000 square feet of space. It includes 150 robots, nearly 30,000 storage bins, 18 carousel ports for picking, 11 conveyor ports for induction, four quality assurance ports, 6,000 feet of conveyor, four carton erectors, 12 protein pick zones with pick-to-light cells, a sortation system, and carton sealing and labeling equipment.
HUMMING ALONG
HelloFresh went live with the Irving AutoStore in 2022 and has been operating at full production since 2023. Company leaders say the system is 25% more efficient and accurate while shipping 20% more recipes compared to the rest of its fulfillment network. One of the biggest benefits is flexibility: Today, HelloFresh can easily expand its menu, adding recipes and ingredients without introducing complexity into the fulfillment process—all thanks to the software integration, synchronization, and the power of the AutoStore.
"This is something we could not have done before," DeGroot says, emphasizing the scale, speed, and flexibility of the system. "And it's the reason we use the Irving facility for expansion initiatives."
The third-party logistics provider (3PL) LVK will partner with Instawork, whose app connects hourly professionals with local jobs, with the partners saying the move will answer a structural shortage of warehouse workers.
The deal will work by integrating LVK’s warehouse operations software with Instawork's network of vetted hourly workers, creating a lever to scale up warehouse operations across North America, they said.
That step is necessary because the warehouse industry can’t find enough workers to support its continued expansion to meet surging consumer demand. In fact, Instawork’s State of Warehouse Labor report has found that 43% of businesses had to forego revenue as a result of insufficient staffing.
"By joining forces with LVK, we are taking a significant step towards empowering warehouses with the tools and labor they need to thrive in today's fast-paced environment," Alex Vinden, General Manager of Light Industrial for Instawork, said in a release. "Together, we are poised to deliver unparalleled value to warehouse operators, ensuring they can meet customer demands with precision and agility."
According to Maggie Barnett, CEO of LVK, the new linkage will equip warehouses with both the labor and the technology they need in today's competitive landscape. "LVK is excited to partner with Instawork to bring transformative solutions to the warehouse industry," Barnett said. "Our combined expertise will empower warehouse operators to enhance their operations, reduce costs, and improve service levels, ultimately driving success in a competitive landscape."
“Consumers pulled back in January, taking a breather after a stronger-than-expected holiday season,” NRF President and CEO Matthew Shay said in the report. “Despite the monthly decline, the year-over-year increases reflect overall consumer strength as a strong job market and wage gains above the rate of inflation continue to support spending. We’re seeing a ‘choiceful’ and value-conscious consumer who is rotating spending across goods and services and essentials and non-essentials, boosting some sectors while causing challenges in others.”
Total retail sales, excluding automobiles and gasoline, were down 1.07% seasonally adjusted month over month but up 5.44% unadjusted year over year in January, according to the Retail Monitor. That compared with increases of 1.74% month over month and 7.24% year over year in December.
Likewise, the Retail Monitor calculation of core retail sales (excluding restaurants in addition to automobile dealers and gasoline stations) was down 1.27% month over month in January but up 5.72% year over year. That compared with increases of 2.19% month over month and 8.41% year over year in December.
NRF says that unlike survey-based numbers collected by the Census Bureau, its Retail Monitor uses actual, anonymized credit and debit card purchase data compiled by Affinity Solutions and does not need to be revised monthly or annually.
As U.S. businesses count down the days until the expiration of the Trump Administration’s monthlong pause of tariffs on Canada and Mexico, a report from Uber Freight says the tariffs will likely be avoided through an extended agreement, since the potential for damaging consequences would be so severe for all parties.
If the tariffs occurred, they could push U.S. inflation higher, adding $1,000 to $1,200 to the average person's cost of living. And relief from interest rates would likely not come to the rescue, since inflation is already above the Fed's target, delaying further rate cuts.
A potential impact of the tariffs in the long run might be to boost domestic freight by giving local manufacturers an edge. However, the magnitude and sudden implementation of these tariffs means we likely won't see such benefits for a while, and the immediate damage will be more significant in the meantime, Uber Freight said in its “2025 Q1 Market update & outlook.”
That market volatility comes even as tough times continue in the freight market. In the U.S. full truckload sector, the cost per loaded mile currently exceeds spot rates significantly, which will likely push rate increases.
However, in the first quarter of 2025, spot rates are now falling, as they usually do in February following the winter peak. According to Uber Freight, this situation arose after truck operating costs rose 2 cents/mile in 2023 despite a 9-cent diesel price decline, thanks to increases in insurance (+13%), truck and trailer costs (+9%), and driver wages (+8%). Costs then fell 2 cents/mile in 2024, resulting in stable costs over the past two years.
Fortunately, Uber Freight predicts that the freight cycle could soon begin to turn, as signs of a recovery are emerging despite weak current demand. A measure of manufacturing growth called the ISM PMI edged up to 50.9 in December, surpassing the expansion threshold for the first time in 26 months.
Accordingly, new orders and production increased while employment stabilized. That means the U.S. manufacturing economy appears to be expanding after a prolonged period of contraction, signaling a positive outlook for freight demand, Uber Freight said.
Part of the reason for that situation is that companies can’t adjust to tariffs overnight by finding new suppliers. “Supply chains are complex. Retailers continue to engage in diversification efforts. Unfortunately, it takes significant time to move supply chains, even if you can find available capacity,” NRF Vice President for Supply Chain and Customs Policy Jonathan Gold said in a release.
“While we support the need to address the fentanyl crisis at our borders, new tariffs on China and other countries will mean higher prices for American families,” Gold said. “Retailers have engaged in mitigation strategies to minimize the potential impact of tariffs, including frontloading of some products, but that can lead to increased challenges because of added warehousing and related costs. We hope to resolve our outstanding border security issues as quickly as possible because there will be a significant impact on the economy if increased tariffs are maintained and expanded.”
Hackett Associates Founder Ben Hackett said tariffs on Canada and Mexico would initially have minimal impact at ports because most imports from either country move by truck, rail or pipeline. In the long term, tariffs on goods that receive final manufacturing in Canada or Mexico but originate elsewhere could prompt an increase in direct maritime imports to the U.S. In the meantime, port cargo “could be badly hit” if tariffs on overseas Asian and European nations increase prices and prompt consumers to buy less, he said.
“At this stage, the situation is fluid, and it’s too early to know if the tariffs will be implemented, removed or further delayed,” Hackett said. “As such, our view of North American imports has not changed significantly for the next six months.”
U.S. ports covered by Global Port Tracker handled 2.14 million twenty-foot equivalent units (TEUs) in December, although the Port of New York and New Jersey and the Port of Miami have yet to report final data. That was down 0.9% from November but up 14.4% year over year, and would be the busiest December on record. For the year, December brought 2024 to a total of 25.5 million TEU, up 14.8% from 2023 and the highest level since 2021’s record of 25.8 million TEU during the pandemic.
Global Port Tracker provides historical data and forecasts for the U.S. ports of Los Angeles/Long Beach, Oakland, Seattle and Tacoma on the West Coast; New York/New Jersey, Port of Virginia, Charleston, Savannah, Port Everglades, Miami and Jacksonville on the East Coast, and Houston on the Gulf Coast.