Logistics
Warehouses have unique energy profiles. Integrar IoT optimizes cold storage, dock doors, lighting, and fleet charging.
Key Metrics
High
Efficiency
99.99%
Reliability
Full
Coverage
3-6 mo
ROI
Why It Matters
A Warehouse Energy Profile Is Unlike Any Other Building
Unlike offices or retail, a distribution center spends its energy on process, not people. Refrigeration systems run 24/7 to hold food and pharma at temperature, dock doors bleed conditioned air every time a trailer backs in, high-bay lighting covers tens of thousands of square meters, and a growing fleet of electric forklifts and delivery trucks needs charging infrastructure sized like a small substation.
The opportunity is equally specific. Because most of this load is controllable and mostly independent of headcount, the same facility can cut 20-30% of its energy with production-linked controls: dock scheduling that limits door-open time, refrigeration that recovers from defrost cycles cleanly, lighting that follows rack activity, and charging that rides the tariff curve instead of fighting it.
Integrar IoT instruments each of these systems and coordinates them from a single warehouse-level dashboard, so logistics energy decisions are made with the same rigor as shipment planning.
Distribution Center Statistics
The Numbers Behind the Racks
Share of a cold-storage DC electricity consumed by refrigeration
Conditioned air lost through a single dock door left open
Lighting savings from high-bay LED with activity-based dimming
Energy reduction achievable across a mixed-temperature facility
Demand reduction possible when EV charging is load-balanced
Refrigeration waste from poor defrost and door discipline
Key Capabilities
Cold Storage
Temperature monitoring for cold chain compliance.
Dock Doors
Reduce conditioned air loss 30-40%.
Fleet Charging
EV fleet load balancing for optimal rates.
Warehouse Lighting
High-bay LED optimization. 40-50% savings.
Building Envelope
Thermal imaging and air infiltration detection.
Multi-Site Fleet
Centralized dashboard tracking energy per shipment.
Deep Dive
Refrigeration, Docks, and the Charging Yard
| System | Where Energy Goes | Optimization Levers | Typical Savings |
|---|---|---|---|
| Refrigeration | Compressors, evaporators, condensers | Defrost scheduling, float pressure, door interlocks | 15-25% |
| Dock operations | Conditioned air loss, air curtains, HVAC recovery | Dock scheduling, high-speed doors, air curtain control | 30-40% of air loss |
| EV fleet charging | Battery charging demand, demand charges | Load balancing, schedule by tariff, smart charging | 20-30% cost |
| High-bay lighting | Continuous rack and aisle illumination | LED, motion-based dimming, daylight skylights | 40-50% |
Cold Chain Discipline
Every time a freezer door opens, warm air floods in and the refrigeration system pays for it twice — once to re-cool the air, once to strip the moisture. Continuous temperature logging in every zone makes door discipline visible, while optimized defrost schedules prevent the wasteful morning spike when every evaporator comes out of defrost at once.
Dock Flow and Air Loss
Dock doors are the largest uncontrolled envelope leak in a warehouse. Linking door activity to trailer arrivals and departure schedules lets the facility batch dock events, so doors open less often and for less time. Combined with high-speed doors and sequenced air curtains, this recovers a third or more of conditioned air that would otherwise escape.
Electric Fleet at Scale
A DC charging 50 electric forklifts and 20 delivery vans overnight can add several megawatts of demand. Smart charging staggers sessions across the night, uses time-of-use windows, and coordinates with site solar. The same platform tracks energy per shipment across the fleet, exposing which routes and sites cost the most to run.
20-30%
Energy Reduction
30-40%
Dock Air Loss Reduced
40-50%
Lighting Savings
$200K
Annual per DC
Compliance & Consistency
Cold Chain Audits Passed Before the Auditor Arrives
Logistics operators carry a heavier compliance load than most: food safety requires documented temperature history, pharma distribution demands continuous cold-chain records, and an increasing number of retailers audit their suppliers' sustainability data. Integrar IoT keeps continuous, tamper-evident temperature logs in every zone and generates the audit-ready reports on demand.
The same interval data powers energy benchmarking across a multi-site fleet. When every DC reports the same metrics — kWh per pallet position, energy per shipment, refrigeration per degree-day — an operator can see at a glance which sites are efficient and which need attention, without waiting for monthly invoices to arrive.
Implementation Path
From a Single DC to a National Fleet
Baseline one pilot site
Sub-meter refrigeration, lighting, HVAC, and charging to build the true load profile of the facility.
Fix the free wins
Repair air curtains, reschedule defrost, re-sequence doors, and dim unoccupied lighting before buying new equipment.
Add charging intelligence
Load-balance EV charging against the tariff and site solar to cut demand charges immediately.
Roll out standards
Replicate the winning control profiles and reporting across every DC, tracked on the same dashboard.
Benchmark continuously
Use cross-site energy-per-unit metrics to drive an annual improvement cycle with documented results.
Optimize Every Watt in Your Supply Chain
Talk to a logistics energy engineer about cold chain optimization, dock door control, and EV fleet charging across your distribution centers.
Get Started