How SiteSense Saved a Cold Storage Facility 656,000 kWh/Year

‍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.

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