Discover how one Midwest cold storage facility slashed energy expenses and achieved energy independence with a strategically designed 1 MW commercial solar installation.
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The Energy Challenge Facing Cold Storage Operations
Cold storage facilities face a unique energy challenge because maintaining the quality and integrity of temperature sensitive products requires reliable refrigeration around the clock. At Evansville Cold Storage in Evansville, Indiana, every frozen food item must remain at optimal temperatures from arrival through distribution, resulting in significant electricity consumption and making energy costs a major factor in the company’s operations and profitability.
Before implementing solar, Evansville Cold Storage faced monthly electric bills ranging from $12,000 to $13,000, representing one of its largest operating expenses. These high energy costs affected pricing, operational flexibility, and long term financial planning, making it essential to find a way to reduce expenses while maintaining the reliable power needed to support its cold storage operations and continued growth.
Designing A Commercial Solar Solution For High-Demand Facilities
When Evansville Cold Storage evaluated solar energy, the available land behind its facility provided the foundation for an effective renewable energy solution. Rather than pursuing a rooftop installation, ECS chose a ground mounted solar array that could be positioned for maximum sunlight exposure. The system also offered easier maintenance access, potential for future expansion, and the opportunity to transform unused land into a productive energy asset without disrupting existing operations.
The resulting 1 MW system, was designed to produce an estimated 1,724,036 kWh annually to help offset the facility’s significant electricity demand. For cold storage facilities and other high demand commercial operations, ECS demonstrates the importance of strategically sizing and positioning a solar installation to meet complex energy needs and maximize long term value.
From Installation To Activation: The Solar Implementation Process
The Evansville Cold Storage solar project became operational in 2020, marking a new chapter in the facility’s energy management while minimizing disruption to its ongoing operations. Because the ground mounted array was constructed on available land behind the facility, installation could proceed efficiently without interfering with the cold storage operation or its critical refrigeration systems. The project also followed a turnkey approach that coordinated design, engineering, permitting, and installation through a single point of accountability, allowing ECS to focus on running its business rather than managing multiple contractors and vendors.
After installation, the system underwent testing, grid interconnection, and performance verification to ensure it was ready to deliver its projected energy production. As Dylan Rexing, President and CEO of Evansville Cold Storage, explained, “We’re busy running our business, we’re not looking for something that we have to go and maintain, and solar checks those boxes for us.” This streamlined process helped establish the foundation for the array’s long term performance and ongoing energy savings.
Measurable Results: Energy Savings And Cost Reduction
The financial impact of the solar installation at Evansville Cold Storage has been substantial and measurable. Before installing solar, the facility’s monthly electric bill ranged from $12,000 to $13,000. Today, that cost is approximately $2,000, representing an 80 to 85% reduction in monthly electricity expenses. The system saves ECS approximately $150,000 annually, allowing the facility to turn one of its largest operating expenses into a more manageable cost while helping provide services to customers at a more competitive rate.
Over the system’s projected 30 year lifespan, ECS expects to save more than $10 million in utility costs. Since becoming operational in 2020, the array has consistently averaged 98% of its estimated annual energy production and savings, demonstrating reliable long term performance. With an estimated payback period of approximately three years, the system has likely already paid for itself, leaving decades of additional savings ahead.
Long-Term Benefits Beyond Immediate Energy Cost Savings
Beyond the dramatic reduction in monthly electric bills, Evansville Cold Storage is realizing long term benefits that extend to energy independence, price predictability, and sustainability. The solar array offsets CO₂ emissions equivalent to burning 136,368 gallons of gasoline annually, helping reduce the facility’s carbon footprint while demonstrating a commitment to responsible and forward thinking business practices. For companies in the cold storage and food distribution industries, where reliability and operational excellence are essential, the project highlights how renewable energy can support both financial and environmental goals.
The system also operates with minimal impact on ECS’s daily operations, generating power while the facility remains focused on maintaining precise temperatures and moving products efficiently through the supply chain. Its ground mounted design provides flexibility for potential future expansion as energy needs grow, creating lasting value for decades to come. For Midwest commercial operations in industries such as cold storage, manufacturing, and food processing, the Evansville Cold Storage project demonstrates how a strategically designed solar installation can deliver significant cost savings, reliable performance, and long term financial and environmental benefits.
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