5 Ways to Slash Warehouse HVAC Energy Costs in Washington

By Five Star Mechanical • Serving King & Pierce Counties | Request a Site Assessment

Warehouses in Western Washington battle wide temperature swings, open dock doors, and high ceilings that trap heat. The fix isn’t one silver bullet. It’s a stack of practical moves that reduce runtime, stabilize comfort, and cut kWh/therms. Start here.

1) Smart Controls: Scheduling, Setpoints, and Zoning

Move beyond manual thermostats. Implement connected controls or a building automation strategy that aligns runtimes to shifts, occupancy, and weather. Use lockouts and deadbands to prevent heating and cooling overlap, and apply night setback/precool for off‑peak savings.

Program dock and staging zones separately from storage zones.
Enable economizers when outdoor conditions allow free cooling.
Trend key points so you can see waste and fix it quickly.

2) Proactive Maintenance: Coils, Filters, Belts, Sensors

Dirty coils, clogged filters, and slipping belts increase fan power and reduce heat transfer. Put your facility on a preventive maintenance plan with seasonal coil cleaning, scheduled filter changes, calibrated sensors, and damper verification.

Bonus: a documented maintenance program supports warranty health and improves reliability during peak seasons.

3) Airflow Management: Stratification, Leaks, and Docks

Tall racks and 30–40 ft ceilings cause temperature layering. Use destratification fans to pull warm air down in winter, and fix infiltration around dock doors, penetrations, and envelope gaps. Seal and weather‑strip to reduce uncontrolled loads.

Add air curtains or vestibules at frequently opened doors.
Balance supply/return paths in racked aisles for smoother airflow.
Keep forklift lanes clear of obstructions near returns.

4) High‑Efficiency Upgrades: VFDs, Advanced RTU Controls, Heat Pumps

Retrofit supply and condenser fans with VFDs, add advanced RTU controls for demand ventilation and optimized staging, and evaluate high‑efficiency heat pumps during end‑of‑life replacements. See our energy‑efficient solutions and ask how we phase upgrades without disrupting operations.

5) Verify & Leverage Incentives

Commission the changes so they stick, then track results. Explore Washington programs for controls upgrades and building performance compliance. When you’re ready, contact our team for a walkthrough and rough savings model.

Frequently Asked Questions

Q. How much can smart controls save in a warehouse?

A. Results vary with schedules and loads, but many facilities see double‑digit percentage reductions after tightening schedules, deadbands, and economizer use.

Q. Are destratification fans worth it?

A. In spaces with high ceilings, yes. Returning warm air to the floor reduces heat loss and shortens runtimes, especially in winter.

Q. Should we replace RTUs or retrofit?

A. Start with lower‑cost retrofits like VFDs and advanced controls. Plan replacements when units near end‑of‑life or when rebates stack favorably.

Q. Can we get rebates in King or Pierce County?

A. Local utilities periodically offer incentives for controls, thermostats, and other measures. Availability changes, so check current programs before purchasing.

Q. How do we show results to leadership?

A. Trend energy use, runtime hours, and zone temps before/after. A short M&V report tied to bills is usually enough to justify rollout.

Reviews

"Five Star tuned our schedules and fixed economizers. Utility bills dropped and comfort improved in the packing lanes." - Operations Manager, Kent

"Rapid maintenance response and clean coil work. Our RTUs finally hit setpoint during peak season." - Facility Supervisor, Tacoma

"Controls upgrade paid back quickly. Dashboards make it easy to spot waste." - Warehouse Owner, Seattle

"Professional team. Minimal downtime during fan VFD retrofit." - Distribution Manager, Auburn

5 Ways to Slash Warehouse HVAC Energy Costs in Washington