A Simulation-Based Approach to Improve Energy Efficiency and Environmental Performance in Warehouses: The Case of IKEA

Given the relevance of warehouse sustainability in the realm of the Logistics 5.0 paradigm, this study evaluates the environmental and economic impacts of green warehousing (GW) measures and provides a practical application to a real business case. A discrete-event simulation approach is applied to the IKEA distribution centre located in Northern Italy to assess strategies for optimizing energy self-consumption from on-site photovoltaic (PV) systems. Three scenarios are identified and investigated: substituting the current mobile material handling equipment (mMHE) fleet with forklifts fully powered by Li-Ion batteries charged through opportunity charging, replacing old PV panels with high-efficiency models, and the combination of both measures. Results are provided in terms of energy, environmental and economic impact, and demonstrate that implementing a Li-Ion mMHE fleet improves energy efficiency and environmental sustainability, achieving a return on investment (ROI) of 26% with a payback period (PBP) of 4 years. Additionally, replacing PV panels increases renewable energy generation by 47%, although some inefficiencies were noted due to on-site energy demand/supply mismatch. Finally, the integration of both GW measures significantly enhances energy and environmental performance, leading to savings that exceed those observed in both scenarios previously evaluated. Findings are discussed and future research directions are outlined.