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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
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
3
Refrigeration
Electric Defrost
Lighting
Office HVAC
Battery Charging Exhaust Fans/Misc Equipment
Where is the energy going?
Typical Heat Loads
• Typical Heat Loads on Refrigeration System include:
• Product
• Transmission
• Infiltration
• Defrost
• Internal Generation
• personnel, lights, other equipment
12/29/104
Energy Balance - Lighting
Light Energy
Heat
Energy
Sound
Energy
Electric Energy
Light is absorbed by product and
structure and re-radiated as heat
energy – this becomes chiller load
Load on Refrigeration System
• 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
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
Upgrading the lighting system results in direct savings from
lighting energy usage reduction and real additional
savings for heat load reduction
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)]
7
Lighting Alternatives
8
• 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
Intelligence
LED power
reduction
(watts)
Incentives
Fine-tuning
HVAC &
chiller load
reduction
Maintenance
Intelligent Lighting SystemSavings Summary
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
9
Sensor Settings & Energy Cost:
Integrated System Maximizes Savings
Sensor Delays and Energy Savings
4:30pm 5:30pm
Sensor
Delay
% “Active” ILE Energy
Cost*
(160W)
HIF Energy Cost*
@ 15 mins (220W)
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 €
* 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
Overview Presentation13
Occupancy data from LightRules system:
Average Occupancy, Week of 27 Sep 3.11%
Average Weekly Occupancy 9%
Case Study – Ardo, UK
Overview Presentation14
•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
Analysis from LightRules system:
Case Study – Ardo, UK
15
Previous
(HPS)
Current (LED)
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
Usage Summary:
Case Study – Ardo, UK
16
Total Annual Energy Savings 750,000 kWh
Tonnes CO2 Saved Annually 400
Simple Payback 1.8 years
Project Summary:
97% Total Energy Savings
• Deployed in the world’s leading industrial facilities
• Cold Storage, Warehouses, Manufacturing, etc.
• More than 200 large-scale deployments
17
Digital Lumens: Tested & Proven
Summary
• Energy Usage in Cold Storage
• Lighting Energy and Heat Load
• Lighting Technology Alternatives
• Case Study – Ardo, UK
18
