Delivering Energy Efficient Temperature Control for Lidl’s Chocolate Storage Facility

The challenge

Lidl’s Regional Distribution Centre (RDC) required a new temperature controlled storage chamber specifically for its chocolate products. The existing ambient storage area needed to be upgraded to maintain a consistent temperature, ensuring optimal conditions for chocolate preservation.

The challenge was to design and deliver an energy-efficient solution while minimising disruption to Lidl’s ongoing operations. As the project took place on an operational site, health and safety considerations were paramount to avoid operational downtime and safety incidents.

Solution

Integral UK Ltd. designed a bespoke system that maximised the use of existing infrastructure to deliver best value. The project included:

• Installation of 9 new glycol coolers and 3 valve stations, with new cabling and controls.
• A new pump set including variable speed drives (VSDs) and a mixing valve arrangement, ensuring accurate and efficient glycol supply to the chocolate chamber.
• Integration of EC fans with -10V control to reduce fan energy consumption
• Adaptation and integration of the existing central glycol plant’s cooling/heating system and controls.
• Installation of a new control system with seamless integration into Lidl’s existing infrastructure.
• Bespoke bracketry and glycol headers, supported by structural assessments ahead of installation.

The works were meticulously scheduled in collaboration with Lidl’s Engineering and Logistics teams to ensure no impact on daily operations. Safety protocols were rigorously followed throughout, resulting in no incidents during the project.

Result

The Chocolate Store project was successfully completed and handed over in line with timeline expectations. Key outcomes included:

• Seamless operational transition, with the chamber meeting its target set point from day one.
• Zero disruption to Lidl’s warehouse activity during the entire project.
• Significant energy savings through use of VSDs and EC fans – estimated at approximately 40% and 30%.
• Optimised cost efficiency by repurposing existing equipment and systems.
• Full training and O&M documentation provided to Lidl’s engineering team, ensuring long term operational success.