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BLOW FILL SEAL (BFS) FILLING ROOM AIR CHANGE RATE REDUCTION

Site: | Location: Australia | Sector: Pharmaceutical Manufacturing

project brief

Existing HVAC system designed to provide Grade A room conditions at high energy cost. Process changes resulted in requiring a Grade C room as background for a BFS filling line.

METHODOLOGY

Phase 1 brief was a trial for 4 out of 8 rooms to reduce air change rate and therefore energy demand while maintaining the required airflow patterns for product protection.
Phase 2 brief was to deliver air change rate reductions on all 8 rooms based on Phase 1 lessons learnt.

SOLUTION

We initially carried out as found testing for airflow measurements, room balance, ‘as found’ airflow visualisation to ISO 14644 methodology. Our recommendations from this included:

Reduce existing air change rates and recommission and balance each filling room.

Validate new air change rates and airflow distribution using airflow visualisation to ISO 14644 methodology

Validate new cleanroom classification to ISO 14644 methodology

Identify and carry out remediation work on an additional AHU resulting in energy savings and potential future breakdown avoidance

Completed to Planned Change Control, FRS, IOQ documentation

These recommendations also reduced annual maintenance costs on fans, motors and filters and reduced noise levels with positive impact on operator working conditions.

Results

Energy savings identified (per year)

455,000 kWh

Energy cost savings identified (per year)

$63,000 USD

Emissions reduction (per year)

387 tonnes

of CO2

EECO2 delivered the HVAC design review, recommissioned the HVAC system and carried out the validation testing to protocol.
We then delivered the additional savings on the remaining rooms based on findings and lessons learned during phase 1.

"Excellent technical knowledge of energy efficiency opportunities and quality of deliverables."
Engineering Director
Global Pharmaceautical Manufacturer

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