Toll warehouse wins national energy efficiency award

Toll Group’s custom-built Nike warehouse in Melbourne’s Altona North has been named Best Industrial Energy Efficiency Project at the National Energy Efficiency Awards 2017.

Now in its sixth year, the National Energy Efficiency Awards recognise and celebrate excellence in energy efficiency, cogeneration and demand management across Australia. 

Toll won the Best Industrial Energy Efficiency Project gong for its recent upgrade to the Toll-Nike facility, which provides specialised warehousing, picking and dispatch solutions capable of handling more than 27,000 stock keeping units (SKUs) and two million units of stock.

The upgrade, completed in May 2017, included the rewiring and reprogramming of the 2.5km conveyor system, 145 electric motors and upgrading 1,300 light fittings to high efficiency LEDs. The re-engineered and streamlined supply chain processes, removed waste and reduced energy use by 54%.

Toll’s Sustainability and Energy Manager, Mark Jones, said the result reflected Toll’s commitment to becoming cleaner and greener. 

“We see environmental sustainability as our corporate responsibility and we’re committed to reducing our environmental footprint. Through Toll’s Smarter Green program we are introducing smarter, more sustainable solutions across all of our operations.

Technology has advanced significantly since Toll and Nike embarked on our supply chain partnership almost 20 years ago. We’ve been working closely with Nike to introduce Smarter Green innovations and this award is a welcome tribute to our lean journey,” said Mr Jones.

The 18,000 sqm warehouse and fit-out were designed with environmental efficiency in mind and features:

  • energy-efficient lighting systems – designed and installed by NuGreen Solutions and powered by best-in-breed LED technology suited to Nike’s warehousing needs. The system also improves visibility and safety, and motion sensors have been fitted to limit power usage to occupied areas.
  • translucent roof sheeting – to maximise daylight so warehouse lighting can be switched off when ambient light is sufficient
  • roof insulation – to assist with temperature control
  • an optimised conveyor system – which was rewired and reprogrammed to operate in relation to product volumes, eliminating unnecessary movement.

The upgrade has led to immediate and significant energy savings. 

“In the first three months after the upgrades were completed, the site’s power consumption has reduced by 54% compared to the same time last year. These are savings we’re proudly passing directly on to our customer,” said Mr Jones.

Nike Pacific Outbound Manager, Ian Black said, “The change to LED lighting in our warehouse has been a great initiative and a real win-win situation. We have reduced our carbon footprint and our electricity costs while improving the quality of our lighting. We commend Toll for sourcing an effective, efficient solution and driving the result.”

Toll added that plans to have the facility certified carbon neutral are now underway. 

“As part of the certification process, Toll will look to have the facility certified under the National Carbon Offsets Scheme and rated by the Green Building Councils Green Star rating system. We’re also keen to replicate the success of this project at other Toll-Nike locations in future,” said Mr Jones.