Cold storage facilities are the backbone of modern supply chains, keeping perishable goods safe and usable across food, pharma, and logistics sectors. But beneath the surface lies a serious challenge: the high and often underestimated cost of energy use. As electricity prices rise and environmental concerns intensify, improving energy efficiency is no longer a nice-to-have, it’s a business necessity.
The True Cost of Staying Cold
Running a coldstore is expensive. Refrigeration systems typically run around the clock and can account for more than 60% of a facility’s total energy consumption. When you add in lighting, pumps, and fans, the cost of simply maintaining temperature control can quickly become the largest operational expense.
It’s not just about the power used to keep products cold, it’s about how well the facility is built and managed to retain that cold. Small inefficiencies can snowball into major losses over time. That’s why energy optimisation is becoming a key focus for operators looking to cut costs and reduce emissions without compromising performance.
The Door Dilemma
One of the biggest yet most overlooked sources of energy loss in coldstores is the door. Every time it’s opened, warm, humid air enters, making the cooling systems work harder to restore optimal conditions. If this happens frequently, or if doors are poorly specified, maintained, or left open longer than necessary, the cumulative impact is significant.
Research shows that air infiltration through doors can be responsible for up to 32% of total heat gain in a typical coldstore. That’s a staggering figure, especially when you consider that even just five hours a day of incorrect door usage could cost close to £24,000 in additional energy consumption annually. On top of that, around 18 tonnes of CO₂e emissions could be added to your carbon footprint.
Smarter Ways to Cut Heat Gain
The good news is that many of these losses are preventable. Installing doors with high thermal performance, using fast-acting or automatic doors in high-traffic areas, and creating airlock systems where possible can all help to minimise heat gain. But equally important is ensuring that doors are used properly.
This means training staff to understand the cost of leaving doors open unnecessarily, carrying out regular maintenance to keep seals intact, and selecting door systems based on their specific environment — considering factors like temperature differentials, traffic frequency, and operational flow.
Even simple interventions like strip curtains or sensor-triggered closing mechanisms can make a noticeable difference. When combined with a broader energy management strategy, these adjustments can help coldstore operators significantly reduce waste, extend equipment life, and improve safety, all while cutting operational costs.
Frequently Asked Questions (FAQ)
Why do cold storage facilities use so much energy?
Cold storage facilities need to maintain low temperatures continuously. Refrigeration systems often run around the clock and may account for most of a facility’s electricity use.
How do cold store doors increase energy costs?
Every time a door opens, warm air can enter the cold area. The refrigeration system must then use more energy to bring the temperature back down.
Can poor door management affect carbon emissions?
Yes. When doors are left open or do not seal correctly, the cooling system has to work harder. This increases electricity consumption and can add to the facility’s carbon footprint.
How can cold storage facilities reduce heat gain?
Facilities can use well-insulated doors and automatic closing systems to limit the amount of warm air entering. Regular maintenance can also help ensure seals continue to work properly.
How can energy management reduce cold storage costs?
Energy management can help operators identify where electricity is being wasted and prioritise practical improvements. Monitoring performance over time can also show whether those changes are reducing energy use.
