Our Complete Guide to Refrigerated Van Conversions

If you’re transporting temperature-sensitive goods, the right vehicle setup is essential. A refrigerated van conversion allows you to adapt a standard diesel or electric van into a reliable, temperature-controlled space, specifically designed to protect your cargo in transit.

Whether you’re working in food delivery, pharmaceutical logistics, agriculture, or frozen goods distribution, the right chiller van helps you stay compliant, reduce waste, and maintain product quality from A to B.

In this guide, we’ll break down the key elements of a fridge van conversion, including what to consider before starting, how the process works, and what to look for in a dependable build.

What to Consider Before Converting a Van to Refrigerated

Before starting a fridge van conversion project, you’ll need to understand how your operational needs will affect the design, components, and cost.

 

Purpose and Usage

Start by considering what you’re transporting and how your deliveries operate. The nature of your cargo and the way it's handled, stored, and dropped off will influence every aspect of your refrigerated van’s design.

• Type of Goods: Food, medicines, flowers, and frozen items all have different requirements when it comes to handling and storage.
• Required Temperature Range: Some loads only need to stay cool (0–5°C), while others need to be frozen (-18°C) or deep frozen (below -25°C).
• Delivery Patterns: If your operations involve multiple stops and frequent door openings, you’ll need solutions that minimise cold air loss and maintain internal temperature.

 

Van Selection

If you’re starting with a van you already own, or planning to purchase one for conversion, consider:

• Size and Format: Short, medium, and long wheelbase vans all offer conversion potential, depending on your payload, access needs, and storage volumes.
• Vehicle Condition: For used vans, it’s important to check structural integrity, mileage, and mechanical reliability. A high-quality conversion relies on a dependable base.

If you’re unsure what’s best for your needs, refrigerated van conversion specialists can help assess your options.

 

Budget and Cost Factors

Conversions can vary in cost depending on the level of specification and complexity. Some key factors include:

• DIY vs Professional: DIY builds can save money upfront but may fall short in reliability, efficiency, and regulatory compliance. Professional conversions cost more initially but often deliver better long-term value, especially in sectors with strict standards.
• Electric vs Diesel: While electric vans come with higher upfront costs, they can lower running expenses and help meet environmental regulations – a major factor if you're operating an electric fridge van in London or another clean air zone.
• Materials and Features: Insulation type, refrigeration system, flooring, racking, and any extras all contribute to the final cost. A good provider will help you balance performance with long-term value.

 

Components of a Successful Refrigerated Van Conversion

A successful fridge van conversion involves several key components that work together to maintain precise temperatures, boost efficiency, and reduce operating costs.

 

Refrigeration Systems

The cooling unit is the core of the vehicle’s temperature control system, and the type you’ll need depends on the van’s power source:

• Diesel / Petrol Vans: These typically use engine-driven compressor systems, which cool the van while the engine is running. Some setups include electric standby capability, which keeps the system running while the vehicle is parked.
• Electric Vans: Because electric vans can’t use engine-driven systems, they require battery-powered or independent electric refrigeration units. These may run off the main battery pack or a separate unit, depending on design.

The right setup depends on your van type, your delivery patterns, and your required temperature range. A reputable conversion partner will help match the spec to your usage.

 

Insulation

Effective insulation is crucial – it’s what keeps cold air in, heat out, and helps reduce energy use during transit.

At Celsius, we use:

• Lightweight, rigid polymer panels
• Insulation made from 100% recycled plastic
• Materials that are fully recyclable at end of life

This approach delivers strong thermal performance to maintain consistent internal temperatures, while also reducing the van’s overall weight – improving fuel efficiency or electric range and supporting sustainability goals.

 

Interior Fit-Out

A well-designed chiller van interior should be durable, hygienic, and tailored to your workflow.

• Shelving and Racking: Fixed or modular options can be tailored to your cargo.
• Flooring: Non-slip or wet-load flooring improve hygiene and safety.
• Extra Features: Waterproof LED lighting, bulkheads, strip curtains, or standby ports enhance usability.

Some setups also include dual-temperature zones, allowing both chilled and frozen goods to be carried together.

 

The Conversion Process: Step by Step

Once you know what you need and what’s involved, it helps to know how the refrigerated van conversion process actually works. Turning a standard van into a reliable, road-ready chiller involves several key stages:

 

Step 1: Consultation

Every successful diesel or electric fridge van conversion starts with a detailed understanding of your operation, including what you transport, how often you deliver, how you load, and where the van will be used.

 

Step 2: Design and Customisation

Based on your requirements, the layout is customised to ensure good airflow, ease of access, and temperature control. Everything from shelving to refrigeration unit placement is mapped out at this stage.

 

Step 3: Insulation Installation

We install lightweight, plastic-based insulation made from recycled materials. It’s thermally efficient, helps maintain internal temperatures, and reduces the carbon footprint of your operation.

 

Step 4: Refrigeration Unit Fitting

A reliable refrigeration system is fitted based on your van type and operational needs, with optional standby modes, electric compatibility, reefer setups, and dual-compartment builds – all designed for consistent performance and temperature control.

 

Step 5: Testing and Handover

Before handover, every refrigerator van is tested for temperature performance, airflow, and operational function. The final product should be ready to meet both day-to-day requirements and relevant compliance standards.

 

Legal & Safety Requirements

Transporting temperature-controlled goods comes with strict compliance obligations. These may include:

• Food Safety: Vehicles must meet food hygiene standards under HACCP frameworks.
• Pharmaceutical Logistics: Cold chain compliance is essential for vaccines, medicines, and samples.
• Regulations: The International Carriage of Perishable Foodstuffs (ATP) 1985 outlines standards for insulated and refrigerated transport.

Choosing an experienced and knowledgeable conversion provider helps ensure that your vehicle will meet all necessary criteria for the goods you carry.

 

What to Look for in a Conversion Partner

If you’re planning to invest in a custom-built refrigerator van, it’s worth taking the time to find the right partner.

1. Relevant Experience: Have they worked with your sector before? Can they demonstrate past conversions similar to yours?
2. Customisation Capabilities: Will they build to your specification, or do they only offer fixed packages?
3. Material Quality: Look for high-performance insulation, durable components, and trusted refrigeration brands.
4. Warranty and Support: Understand what’s covered, how long for, and what aftercare is available should you need repairs or upgrades.
5. Sustainability Credentials: If your business is working toward carbon reduction or ESG targets, ask how the build supports that.