📍 Indonesia Seafood Cold Storage Energy Optimization Project
A seafood export company in Indonesia, specializing in shrimp and fish products.
Initial Challenge
The client operated a 600m² frozen storage facility maintained at -25°C. Rising energy costs and an aging, inefficient refrigeration system were severely impacting profitability. A one-month pre-retrofit energy audit recorded an average monthly electricity consumption of approximately 28,000 kWh, costing around $4,000 USD (assuming local tariff of ~$0.14/kWh). The existing system struggled to maintain temperature during peak ambient conditions.
Core Objective
To implement a targeted retrofit solution that would significantly reduce operational energy costs while enhancing system reliability and control, thereby securing the client's frozen inventory and improving profit margins. Target payback period: <24 months.
Our Solution
The core issue was that the existing reciprocating compressor was old, inefficient for the tropical climate, and the system lacked intelligent controls. Our solution involved a staged upgrade focused on high-efficiency technology and smart control integration without requiring a complete system overhaul.
► High-Efficiency Core Component Upgrade
- We replaced the client's outdated open-type reciprocating compressor with a new Bitzer scroll compressor unit, selected for its superior efficiency, reliability, and part-load performance in high-ambient-temperature environments. The existing condenser and evaporators were retained but thoroughly cleaned and checked for compatibility.
► Intelligent Energy Management System
- We installed a custom PLC-based control system with an energy-saving algorithm. A key feature is a programmable setpoint offset and compressor capacity control that optimizes operation during off-peak hours and adjusts to varying warehouse loading, maximizing cost efficiency without compromising core temperature integrity.
► Proactive System Monitoring
- We integrated a cloud-based remote monitoring system (4G-enabled) to provide real-time operational data (power, suction/discharge pressure, temperatures) and proactive alerts for abnormal conditions, enabling preventive maintenance and ensuring long-term reliability. The client receives weekly performance reports.
Results
✔ Immediate Cost Reduction Post-retrofit energy monitoring over three months showed average monthly electricity consumption reduced to approximately 18,000 kWh. At the same tariff, monthly costs averaged $2,520 USD, delivering direct savings of $1,480 USD per month—a 37% reduction in energy costs for the refrigeration system. Savings may vary slightly with seasonal loading and ambient temperature.
✔ Strong Financial Return The project achieved a simple payback period of approximately 18 months based on energy savings alone, making it a sound investment. Additional benefits from reduced maintenance and improved product security add further value.
✔ Control The modernized system ensures greater temperature stability (±1.5°C vs. previous ±3°C fluctuations). Remote monitoring provides the client with full visibility, security over their core frozen inventory, and data for operational decisions.
Client Says
Client Feedback "The energy savings were clear from the first bill. The system now runs more quietly and maintains temperature much better during the hottest part of the day. I can monitor it from my phone, which gives peace of mind. This investment paid for itself faster than I expected."
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