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D O M E S T I C I N T E R M O D AL C O N TAI N E R S T U D Y
F I N AL R E P O R T
AU G U S T 3 1 , 2 0 1 5
1
Agenda
Executive Summary
Shipping Requirements and Inhibitors
Potential Lanes
Estimated Economics
2
Executive Summary
There are limitations to the ability to ship soybeans in domestic containers
Bulk grain is generally not shipped in domestic containers
Bulk soybeans cannot be shipped in railroad controlled containers, but can be shipped in private
containers controlled by truckload carriers or other intermodal service providers with most railroads
o BNSF does not allow bulk grain shipments in private domestic containers
Inhibitors might be overcome since soybeans are currently shipped in international containers and
domestic container volume would not cannibalized domestic shipments in railcars to any significant
degree
Key intermodal lanes would be through Chicago to soybean crushers and livestock feed markets
Shipments would generally be through intermodal terminals in Chicago
There are potential destinations in the East, Southeast, South, and West Coast
Drayage distances both to Chicago and from destination intermodal ramps to customers in some
cases are long
Intermodal shipments will be higher cost than rail carload shipments
Railcars hold ~100 tons while intermodal containers only hold ~22 tons
Railcar rates are much lower, but are a lower service quality
California shipments have the closest economics of the potential lanes
Certain niches could find intermodal an attractive shipping option
Customers that are not rail served
Customers that require smaller than railcar-load quantities
Customers that require identity controlled soybeans
3
Agenda
Executive Summary
Shipping Requirements and Inhibitors
Potential Lanes
Estimated Economics
4
Domestic and international intermodal are different services. Our focus is on domestic
Domestic International
Current Soybean
Shipments
None Common for exports to Asia –
Low cost backhaul moves
Container ownership Private controlled and
railroad controlled
Private controlled only
Size of Container Almost all 53’ Mix of 20’ and 40’
Transport Modes
Utilized
Truck (drayage) and rail Truck (drayage), ocean vessel,
rail
Our focus is on domestic intermodal
5
Domestic containers are larger than international containers
International
Inside Size Domestic 53’ 20’ 40’ 40’ High
Cube
Length 52’ 6 11/16’’ 19’ 4 ¼’’ 39’ 5 5/8’’ 39’ 5 5/8’’
Width 8 3 7/16’ 7’ 8 5/8’’ 7’ 8 ½’’ 7’ 8 ½’’
Height 9’ 1 ½’’ 7’ 10 ¼’’’ 7’ 10 ¼’’’ 8 ½’’x 8’10 ¼’’
Sources: Hapag-Lloyd; APL Logistics; Union Pacific Railway
Example Domestic Containers Example International Containers
6
Domestic intermodal is a transportation option thatis a combination of truck and rail
Freight is typically loaded into shipping containers which are similar in size to
an over-the-road dry van trailer
Some shipments are in dry van trailers
Each intermodal shipment starts and ends with a relatively short trucking move
(called “drayage”)
Trucks move shipments between the shipper/receiver and the rail terminal
There is drayage on both the origin and destination side of the move
Containers are put on a train for the “linehaul” part of the move – from
metropolitan area to metropolitan area
In many cases the containers are stacked 2 high on a “double stack” train
Intermodal is typically an alternative to over-the-road trucking, not to rail
carload
Intermodal is typically priced at a discount to over-the-road truck of 5-40%
7
There are a number of factors that influence howgood a fit intermodal is for a shipment
Factor Optimal Level
• Origin and destination distance from
intermodal ramps
<75 miles
• Proximity to big cities with regular
intermodal service
<75 miles
• Overall shipment length of haul
• Longer moves are a better fit for
intermodal
>850 miles
• Availability of shipping containers Balance or surplus containers
• Balance in the lane – is it headhaul,
backhaul, or balanced?
Backhaul results in lower rates
• Level of service sensitivity
• Equal to or slower than trucking
• Faster than rail carload
Not high service level requirement
• Attractiveness of the commodity Packaged, palletized products
Source: Zubrod/Clair experience
8
Companies interviewed have concerns about shipping bulk soybeans in 53’ containers
Bulk crops (non-packaged) are not currently shipped in domestic service
Railroads will not want large quantities of soybeans diverted from covered hoppers to intermodal – they prefer it in railcars
Soybeans would weigh out the container (reach the maximum weight) rather than cube out (fill the container volume before reaching weight limits)
Companies have concerns about bulk product in the containers
Product can shift in the container causing uneven weight distribution
o This is a more significant issue for domestic shipments because domestic containers are larger than international containers
o However, the larger size lowers the center of gravity
o Question of whether a soybean container could be on top of double stack
Requires proper blocking and bracing to avoid spills
Potential issues of cleaning containers before or after a soybean load
Carriers would not want the driver involved in loading/unloading
Some level of infrastructure investment would be required at destination for unloading (truck unloading pit, equipment for tipping the containers)
Source: Interviews; Zubrod/Clair experience
9
Several railroads will not ship bulk crops in rail controlled
equipment. At BNSF it is a restricted commodity
Railroads have constraints on shipping bulk crops in their rail-controlled 53’
containers
Union Pacific railroad does not allow bulk crops in their rail controlled fleet.
However, crops can be shipped in private containers
CSX will not ship soybean in railroad controlled containers
NS does not allow bulk crops in their fleet, but would allow it in privates
(according to Celtic)
BNSF does not currently allow bulk crops in domestic private containers
BNSF does not have rail controlled containers – they transport private
containers
Currently crops are a restricted commodity
BNSF is open to test shipments to better understand shipping issues
Stated that there could be an “industry-wide” approach, so test results could
have a significant bearing on the potential for soybean shipments
Source: Interviews
10
While there are inhibitors to domestic intermodal usage, it is possible they can be overcome
Inhibitors Rationale for Supporting Domestic Shipments
• No use of railroad
controlled
equipment (UP,
CSX)
• No bulk shipments
in domestic
containers (BNSF)
• Railroads already ship bulk soybeans in private
international containers for export
• Several railroads would allow shipments in private
containers, including CSX and UP
• If railroads allow soybean shipments in private
containers, they could allow shipments in railroad-
controlled containers
• Railroad fear of large scale move from rail carload
to intermodal could be overcome with education
Source: Interviews; Zubrod/Clair experience
11
Agenda
Executive Summary
Shipping Requirements and Inhibitors
Potential Lanes
Estimated Economics
12
The Chicago-area is the leading U.S. intermodal market
Chicago is a major intermodal hub that the largest railroads all have access to
17 terminals across 6 major railroads
Top US intermodal market: 5.7 M intermodal containers and trailers originated or terminated
The result is that Chicago has the rail and support services and equipment required
Many lanes (east, southeast, south, west)
Frequent service
Large fleet of containers and established drayage
Sources: Association of American Railroads
Major Intermodal Terminals
13
St. Louis and Indianapolis are potential options in certain cases
St. Louis Indianapolis
• Not among the Top 15 U.S.
intermodal markets (cut off of
375,000 annual containers/
trailers)
• Terminals for 4 major railroads
(BNSF, UP, CSX, NS)
• Lanes to the northeast and west
• Shorter dray for certain Illinois
counties
• Mixed interest in routing traffic
through St. Louis by intermodal
providers
• Not among the Top 15 U.S.
intermodal markets (cut off of
375,000 annual containers/
trailers)
• CSX only
• Mentioned by one carrier as an
option
• Shorter dray for Danville area
Sources: Interviews; Association of American Railroads; Google Maps;
Zubrod/Clair experience
14
Soybean production concentration is not close to intermodal terminals
The highest soybean production areas are in Central Illinois – not close to domestic intermodal terminals in Chicago, St. Louis, and Indianapolis
Distance from Chicago (miles):
Gilman: 80
Bloomington: 128
Danville: 136
Champaign: 125
Decatur: 172
Taylorville: 202
Distance from St. Louis
Taylorville: 88
Okawville: 42
Distance from Indianapolis
Danville: 87
Sources: Informa Economics; Google Maps
Illinois Soybean Production
15
Companies we interviewed suggest that there is not a ready supply of empty containers in Central IL
More loaded containers coming out of Central Illinois than going in
Limited access to local empty containers
It is likely containers would have to be drayed (trucked) empty from Chicago/
St. Louis/Indianapolis to Central Illinois to get loaded
If the container is dropped in Central Illinois to be loaded (not “live loaded”)
then it will be important that the drayman has another container to pick up
locally, otherwise it could require 2 round trips from Chicago Central Illinois for
the drayman
Different truck lines and drayage companies may have different balance in
Central Illinois, so it could be a better fit for some than others
Sources: Interviews
16
Potential crusher markets are located in the east, southeast, and south
Shipment would be on CSX or NS
Both have terminals in Chicago
Both have numerous terminals in the East and
Southeast
Lengths of haul (by truck) range from ~450
miles to ~850 miles
Crusher locations would also require drays from
the intermodal ramps
Alabama crushers ~95 miles from Bessemer, AL
CSX terminal
Georgia crushers ~55 miles from Atlanta and ~120
miles from Jacksonville
S. Carolina crushers ~ 65 miles from Charlotte and
~55 miles from Savannah
N. Carolina crushers ~75, 90, and 147 miles from
Greensboro
Norfolk, VA crusher is near intermodal terminals
Currently these facilities receive soybeans from
closer supply points (OH, PA, NY)
Sources: Interviews; Soyatech LLC, Google Maps; Zubrod/Clair analysis
Soybean Crusher Locations
South and East
17
The primary markets for livestock feed are the southeast, south, and west
North Carolina, Georgia, and Alabama livestock markets overlap with soybean crushers
Arkansas livestock market is short haul and not near intermodal terminals
Texas markets are near ~50-80 miles from Houston and ~150 miles from both Houston and Dallas
Northern California market is ~70 to 100 miles from Oakland
Southern California market is ~25 to 75 miles from Los Angeles terminals
Sources: USDA, Google Maps; Zubrod/Clair analysis
Major Soybean Meal Markets
18
Interviewees suggested some of these lanes would be more attractive than others
Most lanes out of Chicago are head haul lanes (the outbound is the primary
flow of goods)
Shipments will not benefit from low backhaul rates, as is the case with export
shipments to Asia
Chicago to California may be somewhat of a backhaul, although some
interviewees suggested this is no longer the case
California livestock feed markets could be attractive due to the long length of
haul and regular intermodal service
Arkansas shipments would be too short a distance and are not close to an
intermodal ramp (e.g., Memphis)
Sources: Interviews
19
Agenda
Executive Summary
Shipping Requirements and Inhibitors
Potential Lanes
Estimated Economics
20
Intermodal will be more expensive than rail carload in most cases
Intermodal is designed to be a price competitive option with truck, not bulk rail
Longer intermodal drayage distances increase the cost of intermodal shipments
A single covered hopper railcar can be loaded to 100 tons or more, while a
single container can only be loaded to about 22 tons*. Hence, 4.5 containers
are required to equal the capacity of 1 covered hopper
Intermodal will have a higher fuel surcharge than rail carload
Intermodal is a much higher service product than rail carload – the soybeans
will arrive to the customer faster and with higher reliability
Intermodal may offer opportunity for improved quality control or identity
preservation from origin to destination
*Some track may be limited to 263,000 gross lbs. so a load of closer to 85 tons
Sources: Zubrod/Clair experience
21
Drayage distance has a significant impact on drayage cost, but location also can be important
Drayage distance impact
the number of trips a single
truck can make in one day
At distances <75 miles,
drayage rates are typically
$200 or less
At distances of 125 to 200
miles, drayage rates are
typically $400 to $600
Some locations have
generally higher and lower
drayage costs y = 2.5043x + 114.51R² = 0.5513
$-
$100
$200
$300
$400
$500
$600
$700
$800
0 50 100 150 200 250
Cost
Miles
TX
Central IL to Chicago
*Excluding fuel surcharge
Source: Intermodal service provider example rates; Zubrod/Clair analysis
Sample Drayage Rates by Mileage*
22
Intermodal rates are far higher than carload rates. Economics to California are the most competitive
Example Lanes Intermodal 1 Intermodal 2 Carload
Champaign, IL - Modesto, CA $149 $85
Dwight, IL - Modesto, CA $111
Okawville, IL - Modesto, CA
(through St. Louis)
$126
Bloomington, IL - Gainesville, GA $102 $118 $51
Champaign, IL - Raleigh, NC $105 $141 $58
Champaign, IL - Center, TX $121 $141 $49
Champaign, IL - Riverside, CA $127 $82
Champaign, IL – Kershaw, SC $119 $54
* Includes fuel surcharge assumed at $3.50/gallon, 22 tons/load for intermodal, live load and unload, 100 tons/load for rail
Sources: 2 intermodal service providers; UP and CSX railroad online tariff rates via their websites
Rate Per Short Ton*
23
Loading heavy containers and lower fuel prices can lower intermodal cost
*Some track may be limited to 263,000 gross lbs. so a load of closer to 85 tons
**Analysis performed based on $3.50/gallon diesel fuel cost
Sources: 2 intermodal service providers; UP and CSX railroad online tariff rates via
their websites; Zubrod/Clair experience
Loading Heavy Containers* Lower Fuel Prices**
• Typical intermodal loads are up to almost
22 tons, or 43,500 lbs. to travel over the
road
• Container net weight capacity is about 28.5
tons. If containers are not moved over the
road, they could potentially be loaded to
this maximum.
• Loading to container net weight capacity
increases product per load by about 30%
• Cost of move to California by Intermodal
Provider 1 decreases to $85/ton, equivalent
to the rail carload cost
• Fuel surcharges are much higher for
intermodal than rail carload
• UP carload fuel surcharges were
about 4% to 8% of freight
charges
• CSX carload fuel surcharges
were about 6% to 8% of freight
charges
• Intermodal fuel surcharges were
about 31% to 32% of freight
charges
• Decreased fuel costs would benefit
intermodal more than carload
24
In some cases, intermodal options through St. Louis can be less expensive* than through Chicago
To Salisbury, MD To Danville, PA To West Coast
• Perdue Farms crusher in
Salisbury, MD
• From Central Illinois to
Salisbury, MD one
intermodal service provider
had shipments from
Champaign, IL routed
through St. Louis, rather
than Chicago
• Dray from Champaign, IL
to St. Louis CSX terminal
is abut 40 miles longer
than to Chicago, but lower
in cost by about $125 per
load ($5.70/ton)
• Boyd Station crusher in
Danville, PA
• Rate from Champaign, IL
through Chicago to
Danville, PA on NS is
$142/ton
• Rate from Okawville, IL
through St. Louis to
Danville, PA on CSX is
$122/ton
• Okawville is about 42
miles from St. Louis
intermodal ramp
• Modesto, CA -area is a
livestock feed market
• Rate to Modesto area is
lower from Dwight, IL
through Chicago than
from Okawville, IL through
St. Louis
• Dwight to Modesto
(through Chicago):
$111/ton
• Okawville to Modesto
(through St. Louis):
$126/ton
* Includes fuel surcharge assumed at $3.50/gallon, 22 tons/load for intermodal, live load and unload
Sources: 2 intermodal service providers; Zubrod/Clair analysis
25
Intermodal shipments have the best relative economics to
California, but could also serve some niches
Intermodal shipments will be higher cost than rail carload shipments
Railcars hold ~100 tons while intermodal containers only hold ~22 tons
Railcar rates are much lower, but are a lower service quality
Lower fuel prices will lower the spread between intermodal and rail carload,
since intermodal is more fuel intensive
California shipments have the closest economics of the potential lanes
Intermodal could be a good fit for certain customer niches
Companies that are not rail served could benefit from direct deliveries in
containers, rather than rail transload to truck for delivery
o Truck cost from transload facility to customer site could add $10/ton or more,
depending on distance
Some company that require less than railcar-load quantities might benefit
from smaller intermodal shipments that also avoid the truck delivery cost
Companies that buy identity controlled soybeans could benefit from
receiving shipment in containers that were loaded at the farm and shipped
intact
26
Potential next steps
Identify shippers and customers that would fit the niches that could make
shipments in domestic intermodal containers attractive
Likely Illinois to California as most attractive lane
Customers that cannot or will not receive by rail
o Not rail served
o Quantities are too low for full railcar-load delivery
o Companies that require identity-controlled soybeans
Assess shipper interest level in intermodal option
Facilitate a trial domestic container shipment on BNSF to pilot customer
Get prohibition lifted
Use success to encourage other railroads to allow shipments in rail-
controlled containers
27
Table of Contents
Executive Summary
Shipping Requirements and Inhibitors
Potential Lanes
Estimated Economics
Appendix
28
We conducted phone interviews of railroads and intermodal service providers
Railroads Intermodal Providers
• BNSF
• CSX
• Union Pacific
• APL Logistics
• Celtic/Transplace
• JB Hunt
• Re-Trans
• Schneider National
• XPO Logistics/Pacer
29
Secondary Research was also conducted of railroad web sites
Union Pacific
Rate finder
Intermodal schedules
CSX Railway
Rate finder
Intermodal schedules
Norfolk Southern
Intermodal schedules
BNSF Railway
Intermodal schedules