Cold Storage & Distribution Facility Performance Turnaround
Overview
The SiteSense monitoring platform identified performance deviations at a cold storage warehouse that indicated significant operational inefficiencies. Using a structured diagnostic process, the facility implemented targeted corrective actions that reduced electricity consumption by 656,000 kWh annually, delivering approximately $98,000 in projected annual energy savings.
Energy Challenges
Performance reviews showed the facility was falling behind expected energy performance targets. While the annual goal was 13.9% energy savings, the site had achieved only 6.6%, creating a shortfall of approximately 171,000 kWh. This gap triggered a deeper investigation into system operation and facility conditions.
Intervention: Checklist-Driven Diagnostic Process
A detailed operational checklist was issued to gather the insights necessary to begin corrective action. Analysis identified several key issues:
Condenser performance limitations: Head pressure was operating at a fixed setpoint instead of using floating condensing pressure based on ambient conditions.
Air infiltration and envelope weaknesses: Sticking doors and damaged barriers allowed warm, humid air into low-temperature spaces, increasing frost buildup and refrigeration load.
Occupancy sensors: Lighting duration was set to 10 minutes, significantly longer than standard operating practices.
Corrective Actions Implemented
- Automated condenser wet-bulb control to synchronize head pressure with outdoor conditions in real time.
- Door and envelope repairs to eliminate infiltration and improve thermal performance.
- Lighting optimization by reducing occupancy timer duration from 10 minutes to 90 seconds.
- Ongoing system optimization, including suction pressure optimization for LT, MT, and ULT systems.
- Condenser fan and pump sequencing optimization.
- Autopurger restoration to improve long-term efficiency by removing non-condensable substances from the system.
Results: Clear & Rapid Performance Improvement
Following implementation of the corrective actions, the facility achieved measurable improvements in energy performance. Energy savings increased by 11.4%, resulting in an estimated annual reduction of 656,000 kWh and projected annual financial savings of approximately $98,000.
656,000 kWh annual energy reduction
11.4% increase in energy savings performance
$98,000 projected annual electricity cost savings
Improved system efficiency through operational and control optimization
Ongoing monitoring and optimization enabled through the SiteSense platform
Key Takeaway
By combining continuous monitoring, digital diagnostics, and targeted operational improvements, the facility transformed underperforming refrigeration operations into a high-efficiency system that delivers substantial and sustainable energy savings.
