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Previous case study

HVAC ENERGY FOCUSSED ASSESSMENT OF AN ASEPTIC PHARMACEUTICAL MANUFACTURING SITE

Client: Global pharmaceutical manufacturer | Location: Italy | Sector: PHARMACEUTICAL MANUFACTURING

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Previous case study

PROJECT BRIEF

EECO2 were commissioned to deliver an HVAC energy focussed assessment of a pharmaceutical manufacturing site working together with the site energy/engineering team and other stakeholders.

The HVAC energy assessment is a proven process that guides the site team to identify and prioritise significant energy and carbon projects that have been discussed in detail and are viable for implementation. The assessment had a scope of reviewing the HVAC energy consumption associated with both GMP (sterile product manufacturing) and non-GMP facilities. It covers AHU, distribution systems and BMS controls and the related energy usage associated with conditioning and moving the air.

METHODOLOGY

The energy assessment workshop process has 3 distinct phases. Each of these are important elements that ensure that the output and conclusions are robust and importantly, that the site team and stakeholders have confidence in the findings and recommendations.

Phase 1: Data collection and analysis;

Phase 2: On site assessment workshop event;

Phase 3: Final report preparation, review and action planning

In preparation for the onsite energy assessment workshop event, EECO2 analysed the HVAC data provided by the site and built a bespoke energy model for assessing the site energy consumption and possible savings from the utility systems, including HVAC consumption. We applied a quality risk based approach to the evaluation to ensure the appropriate measures were adopted to maintain quality and safety, whilst reducing energy costs.

SOLUTION

The data analysis, supplemented by onsite observations, showed that HVAC (air movement, heating, cooling and dehumidifying) was the largest user in terms of energy consumption at 61% of site energy consumption and cost. The main areas of opportunity identified were:

Fresh Air Pre-treatment and dehumidification control

BMS Optimisation set point and dead band control

HVAC set back (or turn down) during non-operational times

HVAC optimisation - air change rates in areas are higher than needed to maintain air cleanliness/classification

HVAC replacement where appropriate

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

13,621,000 kWh

(13,621 MWh)

Energy cost savings identified (per year):

Energy cost savings identified (per year):

€944,000

20% reduction in site energy costs

Emissions reduction (per year):

Emissions reduction (per year):

3,518 tonnes

of CO2 emissions

The energy savings identified have an overall simple payback period of 1.9 years.

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