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The "Flexi-Van": NYC's Revolutionary TOFC Service

Published: December 10, 2024

By: Adam Burns

During its long and storied history the New York Central it credited with pioneering many advancements that shaped the future of rail transport.

Among its notable contributions was the Flexi-Van, a revolutionary freight transportation system that bridged the gap between traditional rail freight and the modern container shipping systems we are familiar with today.

The Chicago Great Western began testing the trailer-on-flatcar (TOFC) idea in 1936, soon followed by the New Haven.  In the post-World War II era railroads continued to expand upon the concept.  

Notably these included the Burlington, B&O, Chicago & Eastern Illinois, Chicago & North Western, Chesapeake & Ohio, Lackawanna, Rio Grande, Erie, Great Northern, Kansas City Southern, Lehigh Valley, Nickel Plate, Santa Fe, Southern Pacific, Wabash, and Western Maryland were all experimenting with intermodal concepts - in particular trailer-on-flatcar or TOFC.

The Flexi-Van was a unique approach to the concept, a sort of containerized version of TOFC that utilized their own specially built spine cars. 

Historically, it is viewed as a success but NYC struggled to convince the industry to sign on to the idea and it had slowly died out by the Penn Central era.

New York Central F7's lead a long freight train near Greensburg, Indiana in July, 1966. Immediately behind the locomotives is NYC's trademark "Flexi-Van" intermodal service.

Genesis

The post-World War II era was a period of rapid change in the transportation industry. As the United States’ economy boomed, the demand for efficient and cost-effective freight transportation solutions grew exponentially.

Traditional rail freight methods, which involved cumbersome loading and unloading processes, were becoming increasingly inadequate to meet the swift pace and volume of modern commerce.

Seeking to address these inefficiencies, Alfred E. Perlman, the then-president of the New York Central Railroad, spearheaded the development of the Flexi-Van system in the late 1950s.

Inspired by the burgeoning containerization movement, which was already gaining traction in maritime shipping, Perlman envisioned a similar solution for rail freight. The concept was straightforward: to create a modular system that could seamlessly transfer goods between different modes of transportation without the need for unloading and reloading cargo.

Design and Implementation

The Flexi-Van system was distinctive for its use of removable containers, or "vans," which could be detached from their base upon reaching a terminal. These containers were similar in principle to modern shipping containers, allowing for easy transfer between trucks, ships, or other trains. What set the Flexi-Van apart, however, was its unique undercarriage system.

Unlike other freight systems, the Flexi-Van did not require the use of cranes or forklifts for loading and unloading. Instead, the vans were mounted on adjustable arms that could slide the container directly onto rail flatcars equipped with turntables, making the transition both swift and efficient.

In their book, "New York Central Railroad," authors Brian Solomon and Mike Schafer note the Strick Division of the Fruehauf Corporation first tested an experimental flatcar with a small motor-driven turntable in 1957.

The container which rode atop this car could be loaded or unloaded by truck trailer at right angles. The first Flexi-Van service was inaugurated in 1958, operating out of New York City's bustling Hudson River docks.

The system quickly expanded, serving major industrial and commercial hubs across the United States. Initially focused on transporting manufactured goods, the versatility of the Flexi-Van system eventually saw it being used for a diverse array of freight, from agricultural products to consumer goods.

Ultimately, NYC wound up with a fleet of 859 Flexi-Van flatcars and more than 7,000 vans/containers.

Impact

For the New York Central, the Flexi-Van was a game-changer. It allowed the NYC to better compete with trucking services, which had been steadily eroding rail market share due to their flexibility and ability to offer door-to-door delivery. By integrating the service, the NYC could offer a similar service, combining the cost-effectiveness of rail with the flexibility of road transport.

The operational efficiencies gained through the system also translated into economic benefits. By reducing turnaround time at terminals and minimizing the labor involved in loading and unloading, the system significantly lowered operational costs. This, in turn, allowed the New York Central to offer competitive rates, attracting a broader clientele and increasing freight volumes.

Broader Influence in the Industry

Beyond the New York Central, the Flexi-Van system had a profound influence on the broader logistics and transportation industry. Its modular approach to freight paved the way for modern intermodal shipping, where goods are transported in standardized containers across different transport modes without being unpacked.

The Flexi-Van's success highlighted the advantages of such systems, prompting other railroads and logistics companies to explore similar solutions. By demonstrating the economic and operational advantages of modular freight systems, the Flexi-Van service paved the way for the industry-wide adoption of containerization.

Challenges and Decline

Despite its initial success and widespread adoption, the Flexi-Van service faced significant challenges.  Most notably was the railroad's struggle to simply get other railroads to sign on.  Ultimately, only the Milwaukee Road and Illinois Central regularly embraced the concept.

As TOFC grew in popularity, typically employing standard truck trailers, the requirement to interchange equipment became increasingly important.  In the end, New York Central gave up on the Flexi-Van and instead joined the TrailerTrain consortium, which is still in service today.

Legacy

While the Flexi-Van itself may no longer be operational, its legacy is indelible in the logistics world. The principles of modular freight transportation it championed, which blossomed throughout the 1980s and 1990s, are foundational to modern shipping. Today, intermodal transportation is a cornerstone of global trade, and many of its practices trace their lineage back to pioneering systems like the Flexi-Van.

Moreover, the Flexi-Van exemplifies the innovative spirit of the New York Central Railroad, cementing its place as a forward-thinking entity in the annals of railroading history. It is a testament to the power of innovation in addressing economic demands, highlighting how visionary ideas can shape industries.

Conclusion

The story of the Flexi-Van service is both a lesson in innovation and a case study in the evolution of freight transport. At a time when the transportation industry faced unprecedented challenges, the Flexi-Van system represented a bold leap into the future, transforming the logistics landscape.

While it ultimately succumbed to the inexorable tides of change and technological advancement, its impact continues to resonate, underscoring the importance of adaptability and foresight in the ever-evolving world of transportation.

Through systems like the Flexi-Van, the New York Central Railroad not only left a permanent mark on the American rail industry but also played a pivotal role in the global evolution of freight logistics, bridging the past with the potential of what was to come.