Fresh produce storage and refrigerated storage: Weak points in the cold chain – The key and foundation to efficiency and sustainability – Image: Xpert.Digital
Sustainable cooling technologies: Optimizing energy consumption in warehouses
The planning and operation of refrigerated and cold storage facilities present particular challenges in terms of energy efficiency. Ultimately, the goal is to store sensitive foodstuffs and other temperature-sensitive goods under optimal conditions while simultaneously minimizing energy consumption and environmental impact. A well-thought-out energy concept forms the essential foundation – from the initial planning phase through construction to ongoing operation. It helps to identify energy losses, uncover potential savings, and pave the way for sustainable and economical operation.
Where is energy being lost? – Weak point analysis in cold storage
Before concrete energy-saving measures can be implemented, it is essential to identify the energy weaknesses of a cold storage facility. Where is cold air lost, where does unwanted heat penetrate, and where is energy used inefficiently?
Typical weak points in the cold chain
Inadequate insulation
Inadequate insulation of walls, ceilings, floors, and doors leads to a constant flow of heat from the outside to the inside. The cooling system has to constantly fight against this heat loss, which drives up energy consumption.
Leaks
Gaps and joints around doors, windows, gates, and penetrations act like thermal bridges. Even small leaks can lead to significant energy losses.
Inefficient refrigeration technology
Outdated refrigeration systems, incorrectly dimensioned components, or inadequate control of refrigeration generation and distribution cause unnecessary energy losses.
Heat input through use
Every opening of doors and gates, the storage and retrieval of goods, the lighting and the use of industrial trucks in the cold storage facility result in a heat input that must be compensated for by the refrigeration system.
Insufficient waste heat utilization
The waste heat generated during refrigeration offers enormous potential for savings. If it is released unused into the environment, valuable energy is lost.
Focus on energy criteria – The levers for greater efficiency
A holistic energy concept for fresh and cold storage facilities takes into account various energy criteria and identifies optimization potential:
1. Power consumption
Electricity consumption accounts for over 70% of the total energy demand of a cold storage facility. The main consumers are the refrigeration system, lighting, and office and break rooms.
Optimization potential
Use of energy-efficient refrigeration systems
Modern refrigeration systems with speed-controlled compressors, heat recovery systems and optimized control technology operate significantly more efficiently than older models.
Lighting concept
Switching to LED lighting reduces the energy consumption of the lighting system by up to 80% compared to conventional fluorescent tubes. Intelligent lighting control systems with occupancy sensors and daylight utilization ensure further savings.
Energy management in the office
Significant savings can also be achieved in the office and social areas through the use of energy-efficient equipment, optimized heating control, and raising employee awareness of the importance of using energy responsibly.
2. Transmission heat losses
Heat losses through the building envelope can be minimized through optimal insulation and the avoidance of thermal bridges.
Optimization potential
High-quality insulation materials
Modern insulation materials such as polyurethane (PUR) or polyisocyanurate (PIR) offer excellent insulation properties with low installation height.
Thermal bridge-free construction
Careful planning and execution of the building envelope can prevent thermal bridges at critical points such as window reveals, door connections and building corners.
Airtight building envelope
An airtight building envelope prevents warm air from the outside from penetrating the cold storage facility and putting additional strain on the refrigeration system.
3. Heat input
The lower the heat input into the cold storage, the lower the energy requirement of the refrigeration system.
Optimization potential
High-speed doors
High-speed doors at the entrances and exits of the cold storage facility minimize opening time and thus reduce heat input.
Heat-insulating curtains
Thermal insulation strip curtains at frequently used passageways act like an additional cold curtain and minimize the air exchange between temperature zones.
Optimized storage
A well-planned storage of goods with sufficient distance between each other and the walls ensures optimal air circulation and prevents the formation of heat islands.
4. CO2 footprint
The CO2 footprint of a cold storage facility is significantly influenced by the energy consumption of the refrigeration system.
Optimization potential
Natural refrigerants
The use of natural refrigerants such as ammonia (NH3) or carbon dioxide (CO2) is more environmentally friendly than the use of synthetic refrigerants with high global warming potential.
Waste heat utilization
The waste heat generated during refrigeration can be used for hot water preparation, heating of office and social spaces, or for other processes.
Photovoltaic system
The installation of a photovoltaic system on the roof of the cold storage facility enables the use of solar energy for electricity generation and reduces the use of fossil fuel-based electricity.
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Investments in energy efficiency pay off.
A well-designed energy concept is the foundation for the energy-efficient and sustainable operation of fresh produce and refrigerated warehouses. Investments in modern refrigeration technology, optimal insulation, the elimination of thermal bridges, and the use of renewable energies pay for themselves through lower energy costs and a reduced carbon footprint. Furthermore, companies benefit from an improved image and increased competitiveness in a market where sustainability and environmental protection are gaining in importance.
Xpert partner in warehouse planning and construction
Weakness analysis in the cold storage
Weakness analysis in cold storage facilities is crucial for increasing efficiency and minimizing energy losses. Here are some of the most common weaknesses and possible optimization measures:
Energy weaknesses
1. Temperature management
Excessively high or low storage temperatures can cause energy waste. A temperature difference of 1°C can affect energy consumption by 3 to 4%.
Measures
Optimizing evaporation temperatures and condenser location to increase efficiency.
2. Insulation
Inadequate insulation of pipelines can lead to significant performance losses.
Measures
Improved insulation, especially in suction lines, to reduce energy losses.
3. Door and gate openings
Frequent opening of doors and gates allows warm air to enter, increasing the need for cooling.
Measures
Installation of high-speed doors and airlocks to minimize cold loss.
Technical deficiencies
1. Outdated equipment
Old cooling appliances can be inefficient and break down more frequently.
Measures
Investment in modern cooling technologies with IoT monitoring for proactive fault detection.
2. Oil separator
The absence of oil separators can impair the efficiency of evaporators and condensers.
Measures
Retrofitting oil separators to increase performance.
Logistical challenges
1. Capacity bottlenecks
Insufficient storage capacity can hinder operations.
Measures
Use of compact storage systems to maximize available space.
2. Shortage of skilled workers
The shortage of skilled workers in demanding environments such as cold storage facilities is a growing problem.
Measures
Automation of processes to reduce staffing needs.
Safety and quality management
1. Interruption of the cold chain
Interruptions can lead to a loss of quality.
Measures
Implementation of SAS (Security Airlock System) systems to prevent cold losses during high goods traffic.
2. Security protocols
Inadequate security measures can increase risks.
Measures
Regular safety inspections and staff training to minimize hazards.
A thorough vulnerability analysis can identify these problems and enable targeted measures to be taken to improve efficiency and safety in the cold storage facility.
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