Isle of Wight large scale frozen distribution centre

The Challenge

Operating a massive 6,750 cubic metre frozen distribution centre demands a large amount of continuous cooling power. This facility in the Isle of Wight was experiencing a common issue, whereby its highest daily energy draw would unfortunately align with the highest tariff energy rate of the day, with peak demand reaching upwards of 135 kilowatts. Additionally, the sheer volume of the space and frequent loading bay activity led to regular temperature fluctuations and highly energy intensive defrost cycles. The operator reached out to us to supply a robust, passive solution to bring their energy costs under control, reduce mechanical wear, furthermore stabilise the internal environment without compromising their overall storage capacity. Their primary goal was to install a solution that would not compromise the core functions of the business, through sacrificing space, or causing lengthy downtime. Glacier Storage Technologies was selected as the sole technology, as it was the only option that met this primary goal.

The Solution‍

Glacier Storage Solutions engineered a comprehensive Thermal Energy Storage system utilising our flagship GlacierCore™ drop in modules. The system was loaded with our E-15 Phase Change Material, which was tested and calibrated for the specific operational requirements of the site. The installation was completed seamlessly within the existing pallet racking, requiring absolutely no structural modifications to the warehouse.

By adopting an active load shifting strategy, the facility now charges the thermal battery overnight when electricity tariffs are at their lowest and ambient temperatures are naturally cooler. During the day, the heavy refrigeration equipment is safely powered down or rested. This strategy successfully reduced their peak daytime demand from 135 kilowatts down to just 113 kilowatts, while securing a massive 28% reduction in freezer energy consumption during active control sessions.

Product Protection and Mechanical Efficiency

The massive thermal buffer provided by the GlacierCore™ modules transformed the operational resilience of the facility. The installation delivered an outstanding 82% improvement in overall temperature stability. Furthermore, because the PCM passively absorbs infiltrating moisture and heat, the facility achieved a remarkable 21% reduction in overall defrost run time, saving thousands of kilowatt hours and drastically reducing mechanical wear on the evaporators.

Long Term Performance and Annual Projections

Following a rigorous four-month autumn analysis, the facility demonstrated a verified 8.40% total energy saving across all operations. These sustained performance metrics project that the total energy saved by the site will reach a massive 60,750-kilowatt hours per annum.

This continuous reduction in power consumption goes far beyond immediate financial benefits. By permanently stripping tens of thousands of kilowatt hours from their annual cooling requirements, the distribution centre has drastically lowered its operational carbon footprint by around 12,575kg per annum. The site has successfully secured a highly sustainable, future proof model that protects the business against peak utility rates, while maintaining uncompromising standards in global product safety.

Conclusion

Securing Long Term Thermal Autonomy

This installation proves that Glacier Storage technology is highly effective in large-scale distribution environments. By intelligently managing their thermal profile rather than simply consuming continuous grid power, the facility is now saving an incredible 60,750-kilowatt hours of energy every single year.

However, the true value of the installation extends well beyond the direct reduction in kilowatt hours. The facility has successfully protected its bottom line by mastering daily load shifting and entirely bypassing premium daytime electricity tariffs. By transforming a static warehouse into a dynamic, intelligent thermal battery, the operator has secured total operational control, maximised mechanical efficiency and is firmly on track to achieve a complete financial payback in just 2.2 years.