How Intermodal Carriers Grow a Profitable Fleet in 2025: Real Costs & Rates
Intermodal trucking has quietly become one of the most resilient sectors in 2025 — especially for small fleets based in major rail hubs like Chicago. But while the freight is steady, succeeding in drayage still requires strategic dispatching, tight cost control, and patience with slow-moving rail operations. In this episode of This Week in Trucking, Sergio Manzo, CEO of Several Trucking LLC, breaks down exactly how his small fleet operates, what costs look like today, and the biggest lessons he learned scaling an intermodal operation from scratch.
Episode Highlights
For small carriers running their own authority — or thinking about getting into containers — this episode offers a rare, transparent look at real numbers from a fleet actually doing the work.
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Sergio’s Story: A Family Legacy in Intermodal
Sergio didn’t fall into trucking — he was raised in it. His entire family works in the industry: owner-operators, dump truck fleets, reefer fleets, and even a parent who spent decades at a steamship line. Intermodal wasn’t a business decision for him — it was the language his family spoke.
After saving money while working in a warehouse, he bought a truck and started as an owner-operator. Several Trucking has been operating since 2018 and recently hit two years with its own motor carrier authority — finally reaching the point where brokers began offering real volume.
Fleet Size, Equipment & Operation Style
Several Trucking currently runs 3 Kenworths (T660s and T900s) with company drivers only, though they plan to add owner-operators once all in-house trucks are consistently staffed.
Their operation is best described as “regional OTR” — typically 250–300 miles one way, with drivers home every night. They move 10–20 containers per week and average $50,000–55,000/month in fleet revenue.
Real Cost Structure: What Intermodal Actually Looks Like
One of the strongest insights from Sergio’s interview is the transparency around costs — something most carriers rarely share publicly.
Here’s what his numbers look like:
- Rate per mile: ~$2.50/mi (round trip, excluding FSC)
- Fuel: $8,000–$10,000/month
- Insurance: ~$3,500/month
- Driver take-home: $1,300–$1,700/week
- Company cost per mile: ~$1.50/mi
- Fleet miles: ~16,000–20,000 miles/month
Because of the variability of rail schedules, consistent work often requires blending local live loads, exports, and drop-and-pick combinations — with dispatching done entirely in-house.
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Why He Stays in Drayage
Intermodal is still one of the few sectors where small fleets can create predictable weekly revenue without chasing the load board. The key is being competitive, responsive, and bidding correctly on sites like LoadMatch.com, where freight forwarders and brokers post container volume nationwide.
The Hardest Part of Intermodal: Imports & Unreliable ETAs
Sergio is blunt: ETAs for imports are never accurate. One delayed vessel or a congested ramp can throw off a full week of planning.
His solution?
He refuses to “guarantee capacity” until containers are actually deramped and show a last free day in the rail yard. That protects the fleet from blocking off trucks for freight that won’t arrive in time — a mistake many new carriers make in their first year.
Scaling Advice: Start Smaller Than You Think
If Sergio could go back, he’d buy fewer trucks and bring on owner-operators first. Not because the revenue wasn’t there — but because the maintenance, breakdowns, and staffing headaches slowed growth more than expected.
His message to new authorities:
- This takes time
- The first 6–12 months will be slow
- At the 2-year mark, the “floodgates open”
- Success comes from consistency, smart networking, and keeping costs tight
Factor Smarter, Grow Stronger
At Bobtail, we help carriers like Golden Key Express stay cash-flow positive with no hidden fees. Get same or next-day payments for the loads you deliver, and free up cash for fuel, insurance, and maintenance — the real costs of scaling a fleet.
Learn more about hassle-free factoring with Bobtail and take control of your business today. Contact us here.
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FAQs
How much does an intermodal carrier typically earn per mile in 2025?
Most small drayage fleets average $2.30–$2.70 per mile round trip, depending on region, FSC, and rail congestion.
What does cost per mile look like for a small intermodal fleet?
Costs commonly fall between $1.40–$1.70 per mile, with insurance and fuel being the largest expenses.
How do small fleets find intermodal loads without load boards?
Platforms like LoadMatch.com, freight forwarder relationships, and direct port/rail connections are the primary sourcing methods.
How can intermodal fleets manage unpredictable import ETAs?
Avoid promising capacity until containers officially deramp and show a last free day in the system.
What type of trucks work best for container hauling?
Lightweight day cabs or efficient sleepers like the Kenworth T660/T900 work well due to drayage weight limits.
How can new authorities build trust with intermodal brokers?
Hit your one-year and two-year authority milestones, run clean safety scores, and maintain consistent communication.
How can a carrier get paid faster after completing a load?
Submit clear, legible paperwork immediately; include in/out times; and use a reliable factoring service like Bobtail for same-day pay.
Where can I stay updated on trucking market trends?
Subscribe to This Week in Trucking’s FREE newsletter for weekly insights on fuel prices, market updates, and interviews with successful carriers who share real strategies that work. Subscribe here.
How does factoring support small intermodal carriers?
Bobtail’s factoring provides no hidden fees, fast payouts, and top-tier support — ensuring carriers get paid immediately for loads that already took days to clear ports and rail yards.
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