How Merlin Eco Green Can Decarbonize Cold Storage—At Scale

Cold storage is essential to food and pharma—but it’s energy-hungry. Most facilities are exposed concrete/steel boxes that soak up heat and leak cold air, so compressors work overtime. Merlin Eco Green replaces that shell with earth-sheltered FRP panels: a lightweight, airtight envelope with high insulation (and minimal thermal bridges). The result is a big cut in refrigeration load—typically ~30% less electricity—with faster builds and longer lifespans.

Why it matters (numbers you can use)

Using our Dubai benchmark (1,000 m² warehouse):

Baseline electricity ≈ 2.439 GWh/year

Merlin savings (~30%) ≈ 0.732 GWh/year

With a grid factor of 0.42 kg CO₂/kWh, that’s ~307 tCO₂/year avoided per 1,000 m² module.

Put differently, each 1,000 m² Merlin cold store is like removing ~67 cars from the road every year (assuming ~4.6 tCO₂/vehicle/year).

What happens when you scale it?

Retrofitted Area Energy Saved (kWh/yr) CO₂ Saved (t/yr) Cars Removed/yr*

1,000 m² 731,707 307 67

10,000 m² 7,317,072 3,073 668

100,000 m² 73,170,720 30,732 6,681

1,000,000 m² 731,707,200 307,317 66,808

5,000,000 m² 3,658,536,000 1,536,585 334,040

*Cars removed uses ~4.6 tCO₂/vehicle/year.

Even a 1 million m² wave of Merlin retrofits cuts ~0.31 MtCO₂ every year—and these reductions persist for decades.

More than energy: compounding sustainability gains

Lower refrigerant risk: Tighter envelopes = smaller systems = less refrigerant charge and leak risk.

Faster construction & lower CAPEX: FRP modules cut build costs (~20% in our Dubai case) and speed time-to-operation.

Water & heat synergies: Merlin sites can capture waste heat for membrane distillation, producing clean water for on-site aquaponic farming—turning a cost center into fresh-food revenue and stronger ESG.

The upshot

Cold storage is everywhere—and so is its energy waste. By swapping the shell (not the mission), Merlin Eco Green turns warehouses into quiet climate wins: less electricity, fewer emissions, faster builds, and optional on-site food and water systems. Scale this across regions, and you unlock megaton-class CO₂ cuts while improving reliability and margins.

 

Annual Energy Savings: ~730,000 kWh

Annual CO₂ Savings: ~306 tons

10-Year CO₂ Savings: ~3,060 tons

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✅ Insight:

Using FRP panels not only cuts CAPEX by 20% and OPEX by 30%+, but also eliminates over 3,000 tons of CO₂ emissions in 10 years — a powerful sustainability credential for logistics, F&B, and pharma cold storage operators.

 

Merlin Eco Green FRP Cold Storage Solution

Executive Summary

Building and operating a 1,000 m² cold storage warehouse in Dubai with Merlin Eco Green FRP panels delivers both financial savings and environmental benefits compared to conventional builds.

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Financial Comparison

CAPEX (Construction Costs)

Conventional build (concrete + insulation panels): USD 1.0M

Merlin Eco Green FRP build: USD 0.8M (20% lower)

✅ Upfront savings: USD 200k

OPEX (Annual Energy Costs)

Conventional warehouse: ~USD 200k/year energy bills

FRP warehouse: ~USD 135k/year (30–35% savings)

✅ Annual savings: USD 65k

10-Year Lifecycle Costs

Metric Conventional FRP Savings

CAPEX $1.0M $0.8M $200k

10Y OPEX (no price rise) $2.0M $1.35M $650k

Total 10Y $3.0M $2.15M $850k

Sensitivity to Energy Prices

Energy Price Growth 10Y Savings (FRP)

0% $850k

+20% $960k

+40% $1.07M

👉 Rising electricity tariffs make FRP even more valuable.

Payback Period

Immediate payback: FRP is cheaper at day one (lower CAPEX + lower OPEX).

Effective annual OPEX savings: $65–87k.

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Environmental Benefits

Annual Energy Savings: ~730,000 kWh

Annual CO₂ Savings: ~306 tons

10-Year CO₂ Savings: ~3,060 tons

✅ Equivalent to removing ~670 cars from the road for a year.

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Technical Advantages of Merlin Eco Green FRP Panels

Superior Insulation: Lower thermal conductivity, minimal leakage.

Fast Build: 30–60% faster assembly due to lightweight modular panels.

Durability: Corrosion-resistant, hurricane-tested, fire-retardant.

Sustainability: Reduced carbon footprint and energy bills.

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Conclusion

For Dubai’s logistics, food, and pharma operators, Merlin Eco Green FRP panels:

Cut build cost by ~20%.

Reduce energy bills by 30–35%.

Deliver $850k–$1.07M savings over 10 years. (Per 1000 sqr meters)

Save 3,000+ tons

CO₂ emissions.

➡️ A compelling financial + environmental case for next-generation cold storage infrastructure.