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LED Lighting Upgrade for Refrigerated Warehouse
Nestlé is the world’s largest food and beverage company with over 2,000 brands including some of world’s most iconic such as Nescafé, Milo, and KitKat. The refrigerated centre in Altona in Melbourne’s west is the first flagship distribution centre that implemented a high automation system.
Project Challenges
While the centre is the first to pilot a cutting-edge automation technology, the facility still relied on outdated, high-pressure sodium lighting, which posed a unique set of complex challenges:
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Around-the-clock Operation: The Altona distribution centre operates 24 hours a day, with a constant flow of trucks and logistics activities. Any interruption to these daily operations would have significant financial and logistical consequences.
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The Refrigeration Burden: Beyond the typical goal of reducing operating costs from high-wattage high bay lights, Nestlé also aimed to alleviate the power usage of the refrigerated site. During hot summer days, the facility found itself exceeding its maximum load, a problem exacerbated by the heat generated from the outdated lighting.
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Technical and Aesthetic Demands: The site’s high ceilings and specific placement of old lights made it difficult for many standard LED replacements to achieve adequate and uniform lighting levels. Furthermore, with the new automation system set to attract visitors from across the business, Nestlé wanted the site to look great and showcase a modern, impressive facility.
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A Strict Deadline: A major barrier was a strict timeline imposed by the installation of the new automation system. This deadline was immovable and would prevent access to certain areas if the lighting upgrade was not completed on time, adding immense pressure to the project schedule.
Our Solution
Next Green Group turned this challenging project into a successful and seamless upgrade. We provided a comprehensive LED lighting solution that addressed every challenge with precision and expertise.
Our team began with a tailored lighting design, carefully engineering a solution that integrated the right mix of high-end products. These lights were specifically chosen for their high output and superior performance, meeting the strict requirements of Nestlé’s procurement team and the on-site staff’s need for optimal illumination.
Working closely with the Nestlé team, we developed a meticulous installation schedule that was strategically incorporated into the project. We executed the upgrade with zero impact on the daily operations of the site, working in different areas at different times of the night and day to accommodate their 24-hour schedule. This strategic approach allowed us to complete the entire installation well before the critical automation system deadline, ensuring no delays and full access to all areas.
The result of Next Green Group’s lighting upgrade completely transformed the Nestlé Altona distribution centre. The new lighting system is now a proud feature of the facility, offering significant reductions in energy consumption, a lighter load on the refrigeration system during peak times, and a safer, more productive environment for staff. The project, once at risk of being abandoned, is now a testament to Nestlé’s commitment to innovation and sustainability,.
Project Gallery
707 lights upgraded to LED
$150,829
Annual cost savings
1,371,173 kWh
Reduction in energy consumption
1,508
Tonnes of CO2 abated annually
90%
Project cost subsidised