Four Reasons Electronic Seals Fail in Real-World Applications

Many in the industry understand that physical seals alone are insufficient, and human error is the biggest reason for continued cargo security failures. However, there’s a reason why no electronic seal on the market has been widely adopted. The truth is that most solutions we’ve seen use outdated technology and cumbersome solutions that create as many problems as they solve in real-world applications. Let’s break down the four most common reasons electronic seals fail in real-world applications:

1. Reusable products create a whole new supply chain.

Electronics are expensive, especially over the last few years, with global supply chain delays and price-gauging. Most manufacturers make reusable products instead, which is great in theory. In reality, this generates a whole supply chain within the supply chain for packaging, shipping, checking, and holding seals from application to application. No company wants to invest time or funding in implementing a whole new process.

2. Disposable batteries have limits.

The life of a container is roughly 15 years. The shelf life of a disposable battery is anywhere from 3-6 years. Picture a company with 40k containers. They install their electronic seals, usually using damaging techniques like drilling, and a few years later, they are faced with disassembling 40k active units dispersed throughout their global supply chain and replacing the batteries. This enormous task requires extensive staffing, training, planning, shipping, and taking containers out of commission for extended periods. It’s unrealistic for a company to take this on.

3. Solar has drawbacks.

Realizing that changing batteries is not an option, many seal manufacturers release electronic seal designs using solar. Solar technology is great but has yet to be fully developed. Rechargeable solar batteries lose capacity, and panels lose efficiency over time. To account for reductions in efficiency, manufacturers will design their electronic seals with higher-end solar panels and batteries. Not only are visible solar panels vulnerable to vandalism, but the more expensive the panel, the more potential for theft.

4. Installation can damage equipment.

A shipping container’s life span is upwards of 15 years. Companies testing electronic seals can’t be expected to damage their cargo by drilling multiple holes into the container or removing whole chunks of steel. Installation must be streamlined and quick to avoid taking containers out of commission, rerouting containers, or causing shipping delays.

We spend weeks on the ground each year traveling along client container routes, working with personnel, and analyzing supply chain data. We know that the only way for electronic seals to be accepted by the market is to account for real-world scenarios.