Zomato Cold Storage Cuts Energy Use by 22.2% with TRUEiSENSE

In cold chain and food logistics, operational margins depend heavily on maintaining precise environmental control while keeping energy expenses under control. Cold storage facilities must run 24/7 to safeguard perishable inventory, but continuous lighting and manual climate checks frequently create hidden operational waste.

To overcome these challenges, Zomato Cold Storage Facility trusted in TRUEiSENSE—India's leader in occupancy-based IoT sensing and true presence technology—to deploy an intelligent motion-sensor lighting and real-time energy monitoring infrastructure.

The result? A 22.2% reduction in lighting energy consumption, an annual electricity bill reduction of ₹14,715, and a 1.34-tonne annual reduction in CO₂ emissions—all while giving operations teams real-time visibility over energy and storage conditions for the first time.

Site Overview & Baseline Operational Challenges

Prior to deploying TRUEiSENSE automation, the Zomato Cold Storage Facility suffered from typical cold-chain infrastructure inefficiencies. Aisle lighting ran continuously across the facility regardless of whether staff were actively picking inventory, driving up energy costs and accelerating bulb degradation.

Existing Challenges Identified On-Site:

• Continuous Lighting Operation: Aisle lighting remained switched ON throughout the day despite intermittent movement, leaving large sections illuminated even when fully unoccupied.
• No Energy Visibility: Without an energy monitoring system to track consumption, load analysis, or peak demand, identifying where electricity was being wasted was nearly impossible.
• No Environmental Monitoring: Manual, interval-based checks left gaps in detecting temperature and humidity fluctuations, risking product quality, compliance, and record-keeping.
• Higher Operational Cost: Continuous lighting drove up monthly electricity bills, maintenance hours, lamp operating hours, and overall operational expenditure.

Key Pre-Deployment Baseline Metrics:

• Total Connected Lighting Load: 42 × 20W LED tube lights (840 W total load).
• Daily Operation: 24 hours continuous operation.
• Daily Energy Consumption: 20.16 kWh per day.
• Monthly Energy Consumption: 604.8 kWh per month.
• Annual Energy Consumption: 7,358 kWh per year.
• Baseline Carbon Footprint: Approximately 6.03 tonnes of CO₂ emitted per year.

The Solution: Integrated TRUEiSENSE Automation & EMS

TRUEiSENSE designed a smart, energy-efficient lighting and monitoring ecosystem tailored specifically for cold storage operations—combining occupancy-based automation, high-efficiency lighting, and continuous environmental & energy analytics on one connected dashboard.

• Motion-Sensor Lighting Automation (CRYOSENSE): 14 sensor-enabled 20W LED tube lights were installed in frequently unoccupied aisles. Utilizing advanced Microwave (MW) motion technology, CRYOSENSE detects presence instantly upon entry, switching lights ON on demand and turning them OFF after inactivity.
• High-Efficiency Operational Lighting: 28 standard motion sensor 20W LED tube lights provide continuous illumination in operational zones where permanent lighting is required.
• Environmental Compliance Monitoring (ATMOS): Industrial-grade temperature and humidity sensors deliver continuous, real-time monitoring, historical records, and instant alerts to ensure cold chain integrity.
• Energy Monitoring System (EMS) & Cloud Dashboard: Continuously measures voltage, current, active power, power factor, daily/monthly consumption, and historical trends on a live dashboard.
• Automated Alarm Notifications: Instant alerts on abnormal temperature, humidity, or power conditions are transmitted via App, SMS, and Email.

Performance Comparison: Before vs. After Deployment

By upgrading to TRUEiSENSE intelligent automation, Zomato Cold Storage achieved immediate, quantifiable energy reductions and operational improvements.

Live Monitoring Proof: 14-Day EMS Telemetry Data

Telemetry pulled directly from the TRUEiSENSE Energy Monitoring System dashboard during a live 14-day monitoring window (26 June – 9 July) compares the sensor-controlled sub-circuit against the standard continuous sub-circuit:

• CRYOSENSE-Integrated Circuit (14 Lights): Consumed 49.29 kWh over the 14-day window with an average power factor of 0.9909 and an average current of 0.70 A.
• Standard Motion Sensor Tubelights (28 Lights): Consumed 106.51 kWh over the same period with an average power factor of 0.9900 and an average current of 1.45 A.

Both circuits maintained a strong power factor above 0.99 and stable voltage throughout the window, confirming consistent power quality alongside the platform's live metering and trend-tracking capability.

Environmental & Sustainability Impact

Beyond direct electricity cost reductions, the deployment lowered the facility's environmental footprint by an estimated 1.34 tonnes of CO₂ annually, supporting Zomato's broader sustainability and corporate ESG objectives through measurable, ongoing reductions.

To put this environmental milestone into context:

• 1.34 tonnes of CO₂ reduction per year is roughly equivalent to removing one passenger car from the road for several months.
• It is comparable to the annual carbon absorption of about 60 mature trees (calculated at ~22 kg CO₂ absorbed per tree per year).

Key Operational Takeaways

1. Extended Hardware Lifespan: Sensor-controlled operation reduces unnecessary run hours, extending lamp life and lowering replacement frequency.
2. Faster, Data-Led Decisions: Real-time energy and environmental analytics replace manual checks, enabling faster maintenance responses and better visibility.

Frequently Asked Questions (FAQ)

Q: How do TRUEiSENSE sensors perform inside sub-zero cold storage environments?

A: CRYOSENSE sensors use advanced Microwave (MW) technology, which detects motion reliably inside cold storage spaces without being affected by low ambient temperatures.

Q: Does lighting automation interfere with warehouse safety or picking operations?

A: No. Continuous lighting is maintained in primary operational zones, while motion-sensor lights illuminate aisles instantly upon entry, maintaining complete worker safety and visibility.

Q: Can the TRUEiSENSE EMS monitor parameters other than lighting?

A: Yes. The TRUEiSENSE Energy Monitoring System is designed to track real-time electrical metrics, voltage, power factor, temperature, and humidity across various sub-circuits and industrial facility assets.

Modernize Your Facility with TRUEiSENSE

Reducing operational expenditure and achieving sustainability goals starts with actionable visibility. Whether you manage a cold storage unit, warehouse, commercial office, or manufacturing facility, TRUEiSENSE delivers true presence sensing and automation solutions engineered to eliminate waste without affecting productivity.

Ready to optimize your facility’s energy consumption? Contact the engineering team at TRUEiSENSE today to schedule your Free Energy Savings Assessment.