Endura Light, the most trusted supplier of long-life lighting for industrial sites across Australia

Case Study: Americold Cold Storage Lighting Upgrade

Tasmania

Client summary

Client: International cold storage provider – regional site

Industry: Cold storage and temperature-controlled logistics

Before the upgrade: Americold’s cold storage lighting challenges

The facility was operating with ageing sodium and metal halide canopy lights installed across multiple buildings. The issues were clear and costly:

High energy bills from 250W and 400W fittings
Frequent bulb failures and difficult replacements in 13-metre-high chiller and freezer ceilings
Rising maintenance costs and ongoing scissor-lift usage required
Low and inconsistent light levels across storage rooms, corridors, and loading areas

The site had been expanded over 15 years, resulting in mixed types of legacy lighting and uneven spacing between fixtures.

Americold Warehouse after, with bright, even lighting

The solution: Endura Light’s approach to the cold storage lighting upgrade

Lighting audit

Endura Light completed a detailed lighting audit of 286 existing canopy fittings across the chiller, freezer, corridor, and staging areas.

We recorded the spacing variations and measured light levels across different room types to understand the exact lighting requirements.

Lighting design

A full industrial lighting design was completed to achieve consistent results across every building.

We kept costs down by using a one-for-one upgrade wherever practical, supported by targeted reductions in fixture counts in key areas, keeping project costs down and improving ongoing energy efficiency.

Products installed

The final solution included a mix of:

100W canopy lights with wide-angle beams in low ceiling loading bay areas
125W canopy lights with pallet aisle beams
150W canopy lights with pallet aisle beams

Every fitting was supplied with Smart Dimming Controllers. These allowed the lights to dim in two stages when areas were unoccupied, and instantly all lights in a given aisle or space returned to full output when people or forklifts entered the zone.

Custom modifications to the luminaires helped reduce installation time. The project achieved an impressive 22-minute average changeover per canopy fitting.

This approach is ideal for industrial cold storage facilities that depend on reliable cool room lighting to maintain safety and efficiency.

Why this approach worked

Aisle beams delivered major wattage reductions of 20-30W per fitting while improving uniformity along pallet racking.
Multiple wattage options allowed us to compensate for inconsistent fixture spacing across the six different building stages.
Wide 110° beams improved lighting uniformity in the lower loading and dispatch areas.
Smart Dimming ensured maximum energy savings without compromising safety or workflow.

The result was a fully optimised system that improved visibility and reduced ongoing operating costs across the entire site.

After the upgrade: results and improvements

The upgrade produced significant energy, visibility, and maintenance improvements.

Quantifiable improvements

91% reduction in lighting energy consumption, plus extra energy savings from reduced refrigeration load.
Average of three man-days saved per year on maintenance, with no more scissor-lift hire for bulb replacements.

Light level improvements

Storage rooms: 80-125 lux to 275 lux
Corridors: 240 lux to 275 lux, using half the number of fittings
Staging areas: 590 lux to 725 lux

Before & after images

Corridor (before)

Americold Corridor area brightly lit after Endura Light LED installation

Corridor (after)

Americold High-bay pallet racking before with poor quality lighting

Pallet aisle (before)

Americold High-bay pallet racking after, with bright, even lighting

Pallet aisle (after)

Warehouse (before)

Warehouse (after)

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