Enhancing Energy Efficiency Through Smart Door Management for Lidl Distribution Centres

The Challenge

Lidl operates multiple multi temperature distribution centres across the UK, with chambers ranging from -24 degrees freezer spaces to +14 degrees fruit and vegetable storage areas.

Each chamber is accessed through rapid rise doors, but frequent door malfunctions and improper usage were leading to excessive energy consumption. When doors were left open for extended periods or remained broken, temperature control systems had to work harder to maintain required conditions. This not only increased energy costs but also risked failing critical technical audits due to products not being stored at the correct temperature.

To address these inefficiencies and drive sustainability, Integral have addressed an innovative solution to monitor and optimise door usage.

The Solution

Through a collaboration with JLL Technologies, Integral implemented a cutting edge solution using Disruptive Technologies’ wireless proximity sensors.

These sensors were installed to track real time door activity, identifying operational inefficiencies and ensuring proper maintenance.

Integral provided Lidl with weekly reports analysing door usage patterns. This data enabled Lidl to set KPIs for operational teams, fostering behavioural change that improved energy efficiency.

Results

• Lidl’s investment in this technology driven solution yielded significant benefits:
• Reduction in prolonged door openings by 85% across monitored sites.
• Annual emergency call-out costs reduced within six months.
• National contract awarded to Integral UK for full implementation
• Improved compliance with internal product temperature audits, ensuring food safety and reduced operational disruptions.
• Enhanced energy efficiency, contributing to Lidl’s net zero goals.

By leveraging smart monitoring solutions, Lidl not only optimised energy consumption but also strengthened operational performance across its distribution network.