Glasgow, UK: Tesco achieved an average 10% energy saving at eight distribution centres between January 2022 and September 2023 by better managing the operation and maintenance of refrigeration and heating equipment at its sites.
Monitoring and data management by Star Refrigeration’s Ethos service and StarCare maintenance were the key to success. Star Data Analytics Ethos, combines artificial intelligence with real-time data analysis specifically designed for refrigeration and heating equipment, according to a report on the upgrade.
The technology allowed Tesco to also rethink chiller temperatures at the test sites in order to reduce energy demand. Ethos is described by Star Refrigeration as a “smart monitoring service” that can be retrofitted into industrial cooling and heating systems to collect and use operational data to better understand how systems can be improved.
Some of the features of the system include assisting with the earlier identification of issues within refrigeration systems that could affect operational efficiency if unchecked. It can also be used to assist engineers to understand energy performance gaps in a site. The technology was first installed at three of Tesco’s distribution sites – before being expanded to five other locations.
Star Refrigeration said the technology allowed it to provide useful information and data that could be acted on by its StarCare team, which provided maintenance services to Tesco. This allowed for operational improvements to be introduced at the testing sites. In certain cases, this was done without creating additional cost while improving system efficiency, Star Refrigeration says.
During the project changes included targeted repairs and purging air from condensers. Ageing condensers were also replaced as part of planned expenditure by the retailer on the test sites.
Star Refrigeration said that Ethos identified that an annual reduction of energy demand of 330,000 kWh was possible through the changes at Tesco’s sites. These changes allowed for the company to balance system efficiency and energy conservation with effective product management.
The case study noted that Ethos had also identified other opportunities to rethink temperature set points based on seasonal climate conditions. It stated: “In winter, when the ambient temperature is lower, the refrigeration system can operate more efficiently, allowing for a higher set point. Conversely, the set point is lowered in summer to counteract the higher ambient temperatures.”
The eight distribution sites that were part of the pilot project were based in Livingston, Doncaster, Hinckley, Widnes, Avonmouth, Daventry, Dagenham and Southampton. The testing took place between January 2022 and September 2023.
Average savings in energy demand of 10% were introduced across the sites. The largest efficiency gains were realised at Tesco’s Hinckley site that saw a 20% demand reduction.
Dr Rob Lamb, marketing director, Star Refrigeration, said that the Tesco trial has shown the value of a system such as Ethos in cold store operations. “Tesco has been able to make notable energy savings, further optimising its energy use and lowering carbon emissions, while ensuring cost-effective refrigeration across its distribution network in what has been a relatively short period of time.”
Rob Redfern, Tesco Group energy manager working on renewable and low zero carbon, said: “The insights that Ethos and the Star Refrigeration team have delivered have been invaluable and allowed us to make targeted changes at each of the eight distribution sites in a strategic manner, often with no additional spend required.
“We’re very proud to say that we have reduced energy consumption by an average of 10% across those distribution sites in the short period between January 2022 and September 2023, achieving a return on investment in under three months.”
Star Refrigeration’s collaboration with Tesco was chosen as one of two finalists for the inaugural Institute of Refrigeration, ‘Beyond Refrigeration Environment award made earlier this year.
