Reducing Warehouse Energy Consumption: Tips and Tactics

 Here are some sobering statistics to start us off. One single (non-refrigerated!) warehouse can consume as much as 6.1 kWh per square foot per year.

The average consumption of natural gas for non-refrigerated warehouses is 134,000 BTUs per square foot, per year.

Heating, cooling, and lighting, in sum, account for approximately 90% of energy consumption in a non-refrigerated warehouse.

Unfortunately, without energy-efficiency protocols in place, and energy saving fixtures and lighting, much of this energy can be considered wasted - at least in most instances.

Fortunately, there is a lot you can do about it, and the best part is that improving your warehouse’s energy efficiency isn’t just good for the environment, it will impact your bottom line.

Here are some basic suggestions.

Power Non-Critical Machines and Infrastructure Down When Not in Use

Idle time is an immense parasitic drain on your electrical supply. Invest in machines and equipment that can be easily automated, and power down machines, tools, computers and other equipment, including lighting (even energy-efficient LED light bulbs), when they are not in use.

Allowing a machine, such as a conveyor or even a computer, running when it is not in use is immensely wasteful and consumes energy pointlessly.

On top of the fact that idle time wastes energy, it also decreases the lifespan of most machines and tools, which brings up another point. Where possible, service machines, tools, and other equipment during this planned downtime, to extend their service lifespans, saving you even more money.

Replace Your HID Bulbs with Corn Cob LED Lights

Heating and lighting alone can account for up to 76% of total energy consumption in a warehouse that is not refrigerated, and the two systems are interrelated - which we will cover here.

For one, many warehouses still use HID lights in their low and high-bay lighting fixtures. After all, for a while HID lights, like metal halide and high pressure sodium lights, offered the best bang for your buck. They are efficient, produce excellent luminous output in a wide range of color temperatures, and offer pretty good service lifespans.

But there’s a catch. As good as they are, they don’t last nearly as long as corn cob LED light replacements. Most HID lights last somewhere between 2,000 and 3,000 hours, although they can last as long as 15,000 hours. That doesn’t sound so hot next to your average LED corn light’s lifespan, which is 50,000 hours, if not longer.

Speaking of things being hot, that’s another thing - HID lights burn extremely hotly, and produce a lot of heat as a byproduct. They can substantially contribute to overall cooling costs of your warehouse in the summer, because your lighting and cooling systems will be counteracting each other. The point is by switching your HIDs to corn cob LED lights, you can save on both lighting and heating.

Also, for what it’s worth, most HID lights have toxic components like sodium and mercury which complicate disposal since they are considered hazardous waste. Corn cob LED lights are not, and have no hazardous components.

Keep Your HVAC System Up to Snuff

A laboring HVAC system - whether for heating, cooling, or both - can substantially impact your warehouse’s overall energy consumption and efficiency.

The older an HVAC system is, and the more continuously it is used, the harder it will work to perform. Aging internal parts, dirty filters, and other components can hamstring a heater or air conditioning system.

In order to keep things running smoothly, best practice is to have commercial and industrial heating and cooling systems serviced by a certified technician at least twice a year, if not more frequently. The best times to do so are usually in the spring and the fall, since these are usually when the systems are under the least strain, and it’s a good habit to schedule maintenance ahead of time.

If possible, you should also install a programmable system, which will allow for more precise and optimal utilization of your HVAC system.

Install Industrial Ceiling Fans

Huge industrial ceiling fans, also called HVLS fans, are not just there for the warehouse ambiance. They can have a serious (positive) impact on your warehouse’s HVAC costs.

Yes, it costs power to run them, but they also circulate air more efficiently in the warehouse, which is central to keeping down energy costs.

Specifically, they improve heating efficiency in the winter, when cold, dense air pools around the warehouse floor. Try as your heating system might, most of that hot air will linger by the ceiling - but not if you have industrial ceiling fans installed, which will force it down closer to the floor level.

Investigate Solar Power

Solar power is another way your warehouse might be able to offset its energy consumption. Just think of all that wasted space on the warehouse roof - that could be potentially raking in energy from the sun every day.

Of course, it depends where the warehouse in question is located, as well as what the prevailing weather patterns (and regulations) are, but solar power can be a great way to improve efficiency.

Depending on the efficiency of the system, you may be able to seriously decrease your operation’s electricity expenditures.

Implement an Effective Industrial Automation System

Industrial automation systems with smart controls can help a team of warehouse supervisors substantially improve operational efficiency and reduce downtime, improving productivity and cutting back on wasted energy.

Industrial automation can help minimize accidents, downtime, and smart equipment may even have efficiency settings that reduce energy use by minimizing idling or through other controls.

We sell a wide range of industrial automation equipment and parts compatible with automated systems here, including but not limited to industrial connectors and cable glands, AC cooling fans, alarms, conduit systems, chargers, ethernet connectors and switches, LED corn bulbs, and fixtures, power cords, relays, wire and cable accessories, LED tower and signal lights, and much more.

Take a look through our collection and if you have questions about anything we sell, or for more energy saving tips for warehouses and industrial facilities, get in touch with us at 800-966-2345.