Lighting in Cold Storage

Aaron Kless, PE
Director of Application Engineering
Digital Lumens

Agenda

• Energy Usage in Cold Storage

• Lighting Energy and Heat Load
• Lighting Technology Alternatives
• Case Study – Ardo, UK

2
 Typical Cold Storage Energy Profile

Where is the energy going?

Battery Charging Exhaust Fans/Misc Equipment

Office HVAC

Lighting
Refrigeration

Electric Defrost

3 SOURCE: A. Lekov, L. Thompson, A. McKane, A. Rockoff, M.A. Piette, Opportunities for

Energy Efficiency and Automated Demand Response in Industrial Refrigerated Warehouses in
California (2009), Lawrence Berkeley National Laboratory

Typical Heat Loads

• Typical Heat Loads on Refrigeration System include:

• Product
• Transmission
• Infiltration
• Defrost
• Internal Generation
• personnel, lights, other equipment

4 12/29/10
 Energy Balance - Lighting

Electric Energy
Heat
Energy

Sound
Energy

Light Energy

Light is absorbed by product and

structure and re-radiated as heat
energy – this becomes chiller load

Load on Refrigeration System

Number of Lights 100

Light Fixture Power (HPS) 465 W
Total Lighting Power 46.5 kW
Total Lighting Power (BTU/hr) 158,658 BTU/hr
Max Refrigeration Load 13.2 Tons Refrigeration

• Assuming steady state operation, 90% Load Factor

• The chiller will have to remove 1.25 billion BTUs of energy each
year from the lights alone - enough energy to melt over 4,300
tons of ice!

6
 How Much Are You Spending To Remove
Heat From Lights?

• Typical Coefficient of Performance

(COP) for Industrial Refrigeration
System is 2-5

• COP = [(heat energy removed)/(system energy input)]

Upgrading the lighting system results in direct savings from

lighting energy usage reduction and real additional
savings for heat load reduction

Lighting Alternatives

• Lower energy alternatives include HIF, LED, and LED with

intelligent controls
• The key to significant energy usage reduction in cold storage
is taking advantage of control systems
Intelligent Lighting System
Savings Summary
Incentives
LED power
Fine-tuning reduction
(watts)

HVAC &
chiller load
reduction

Maintenance
8 Intelligence
 Fine Tuning Controls

• Motion Sensor timeout has a

significant impact on energy
savings
• Shorter timeouts drive greater
savings
• Low time threshold is technology
driven
• Solid state lighting lifetime not
affected by excessive cycling

Sensor Settings & Energy Cost:

Integrated System Maximizes Savings
Sensor % “Active” ILE Energy HIF Energy Cost*
Sensor Delays and Energy Savings Delay Cost* @ 15 mins (220W)
(160W)

30 sec 25.2 % 27.13 € 147.29 €

60 sec 40.8 % 44.19 € 147.29 €

90 sec 52.4 % 56.59 € 147.29 €

3 min 72.5 % 79.07 € 147.29 €

5 min 89.3 % 96.90 € 147.29 €

10 min 98.6 % 106.98 € 147.29 €

4:30pm 5:30pm

* 10¢ /kWh
 Case Study – Ardo, UK

• Frozen Vegetable Distribution Center

• 80,000 cubic meters
• Movable racking system
• -27 °C
• 7,000 operating hours/year
• 165 x 400W High Pressure Sodium Fittings (456 W)

11

Case Study – Ardo, UK

Solution:

• Digital Lumens Intelligent LED

Lighting System installed in July of
2012
• 165 x 160W ILE HB-3 fixtures with
LightRules control and monitoring
system
• Motion sensor and wireless controls
integrated into every fixture

12
 Case Study – Ardo, UK

Occupancy data from LightRules system:

Average Occupancy, Week of 27 Sep 3.11%

Average Weekly Occupancy 9%
13 Overview Presentation

Case Study – Ardo, UK

Analysis from LightRules system:

•Extending motion sensor timeout from one minute to fifteen minutes would
drive light usage up by over 2.5 times
•Short sensor timeout drives significant savings

14 Overview Presentation
 Case Study – Ardo, UK
Usage Summary:

Previous Current (LED)

(HPS)
Annual Direct Lighting Energy Usage 540,000 kWh 20,200 kWh

Annual Lighting Heat Load 1.8 x 109 BTU 6.9 x 107 BTU

15

Case Study – Ardo, UK

Project Summary:

Total Annual Energy Savings 750,000 kWh

Tonnes CO2 Saved Annually 400

Simple Payback 1.8 years

97% Total Energy Savings

16
 Digital Lumens: Tested & Proven

• Deployed in the world’s leading industrial facilities

• Cold Storage, Warehouses, Manufacturing, etc.
• More than 200 large-scale deployments

17

Summary

• Energy Usage in Cold Storage

• Lighting Energy and Heat Load
• Lighting Technology Alternatives
• Case Study – Ardo, UK

18
 Questions?

19

Thank You
Aaron Kless, PE
akless@digitallumens.com
support@digitallumens.com