Cold Storage Warehouse Achieves 90% Lighting Energy Reduction with LED High Bays

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Cold Storage Warehouse Achieves 90% Lighting Energy Reduction with LED High Bays

Case study shows how Cloverleaf Cold Storage replaced HID lamps with Flex LED high bays and controls, cutting 824k kWh and achieving 1-year payback in a 300,000 sq ft freezer facility.

Published

June 4, 2026

Read time

3 min read

Source

Cloverleaf Cold Storage upgraded lighting across a 300,000 sq ft Columbus, OH cold storage warehouse operating 24/7 at sub-zero temperatures. The project replaced 170 600W HID fixtures with Flex Essential Series 4.0 LED high bays rated to -40C, integrated with occupancy sensors and scheduling. Results included 90% energy reduction, 824,224 annual kWh savings, elimination of lighting heat load in freezers, and improved worker safety. The same solution was later rolled out to nine additional sites for a corporate total of 13 million kWh saved annually.

Key takeaways

LED high bays rated for -40C delivered 90% energy reduction versus HID in freezer environments

Occupancy sensors and scheduling cut annual consumption by 824,224 kWh with 1-year payback

Removal of lighting heat load reduced refrigeration demand in 24/7 cold storage operations

Rotatable modules and integrated controls improved aisle and rack illumination uniformity

Single-site success led to replication across nine additional Cloverleaf facilities

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