Award-winning warehouse reduces energy use by over 50%

Toll Group has been recognised at the National Energy Efficiency Awards 2017, taking out the award for Best Industrial Energy Efficiency Project for its recently upgraded Toll–Nike facility.

Based in Melbourne, the Toll–Nike facility provides specialised warehousing, picking and dispatch solutions capable of handling more than 27,000 stock keeping units (SKUs) and two million units of stock. NuGreen Solutions was recruited to upgrade the 18,000 m² warehouse as part of Toll’s Smarter Green program.

Completed earlier this year, the upgrade featured the installation of energy-efficient lighting systems designed by NuGreen and powered by LED technology suited to Nike’s warehousing needs, with 1300 light fittings to high-efficiency LEDs. Motion sensors have also been added to limit power usage to occupied areas.

It also included the rewiring and reprogramming of the warehouse’s 2.5 km conveyor system, optimising it to operate in relation to product volumes and eliminating unnecessary movement.

Other features of the upgrade include translucent roof sheeting, to maximise daylight so warehouse lighting can be switched off when ambient light is sufficient; and roof insulation, to assist with temperature control.

“We see environmental sustainability as our corporate responsibility and we’re committed to reducing our environmental footprint,” said Toll Sustainability and Energy Manager Mark Jones. “Through Toll’s Smarter Green program we are introducing smarter, more sustainable solutions across all of our operations.”

The upgrade has led to immediate and significant energy savings, with Jones claiming, “In the first three months after the upgrades were completed, the site’s power consumption has reduced by 54% compared to the same time last year. These are savings we’re proudly passing directly on to our customer.”

“The change to LED lighting in our warehouse has been a great initiative and a real win-win situation,” added Nike Pacific Outbound Manager Ian Black. “We have reduced our carbon footprint and our electricity costs while improving the quality of our lighting. We commend Toll for sourcing an effective, efficient solution and driving the result.”

Jones said that plans to have the facility certified carbon neutral are now underway, noting, “As part of the certification process, Toll will look to have the facility certified under the National Carbon Offsets Scheme and rated by the Green Building Councils Green Star rating system. We’re also keen to replicate the success of this project at other Toll–Nike locations in future.

“Technology has advanced significantly since Toll and Nike embarked on our supply chain partnership almost 20 years ago,” he continued. “We’ve been working closely with Nike to introduce Smarter Green innovations and this award is a welcome tribute to our lean journey.”

Hosted by the Energy Efficiency Council (EEC), the sixth National Energy Efficiency Awards were announced at the National Energy Efficiency Conference 2017 Gala Dinner in November. Aside from the warehouse upgrade, the following awardees were recognised:

• Best Innovation in Energy Efficiency 2017: MATRIXX — an intelligent LED lighting platform designed by Vivid Industrial for the industrial and commercial markets.
• Best Energy Savings Program 2017: The Victorian Government’s Victorian Energy Upgrades — a program providing households and businesses with access to discounted energy-saving products and upgrades through accredited providers.
• Best Commercial Building Energy Efficiency Project 2017: Enhancing energy efficiency at the MCG — a project delivered by Melbourne Cricket Club and Siemens.
• Leading Energy User 2017: Unity Water — banking sustainable year-on-year energy savings and fostering change across the business, making energy-efficient operation a part of business-as-usual.
• Best Residential Energy Efficiency Project 2017: Switch Your Thinking — a local government energy efficiency program working with the community to find innovative solutions to electricity problems.
• Best ‘Smart’ Energy Project 2017: RMIT University’s Sustainable Urban Precincts Program — a $128m commitment to reduce emissions associated with university operations (25% by 2020) while also delivering a step-change in asset management practices and end-user experience.
• Young Energy Efficiency Professional 2017: Jason Harrison, Airmaster — a strong advocate for energy efficiency in the HVAC&R Industry with his vision to move towards a more data-driven industry with energy efficiency at the forefront.
• Energy Efficiency Champion 2017: Alan Pears, RMIT — considered the ‘go to’ authority on energy efficiency, having teased out the complexities and absurdities of energy and climate policy in Australia for the past 30+ years.