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Previous case study

IDENTIFYING HVAC ENERGY REDUCTION STRATEGIES AT A PHARMACEUTICAL MANUFACTURING FACILITY

Client: Global top 10 pharmaceutical company | Location: China | Sector: CONSUMER HEALTH PRODUCTS

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Previous case study

PROJECT BRIEF

To identify HVAC energy reduction strategies throughout various key manufacturing and storage spaces at a single key manufacturing site and quantify potential cost savings.

METHODOLOGY

Data was requested from the client site on the energy consumption, HVAC system design, operation and critical product quality requirements in key process (higher grade GMP) areas.
EECO2 analysed this data to determine the likely opportunities for efficiency improvements. These were evaluated and discussed with key stakeholders, to determine a viable site plan to implement the improvements identified.

SOLUTION

We identified a number of strategies with significant cumulative energy savings, including:

Add VSD to extraction fans in several key areas to enable fresh air to be reduced

Reduce air change rates

Introduce temperature and relative humidity deadbands

Introduce PID loop tuning

Install control sensors and implement turn off strategy for finished goods warehouse

Our recommendations included a practical plan for implementation including budgets and payback period. This project assessed 43% of the site HVAC energy consumption, and therefore recommended a thorough, focused review of non-classified areas, including secondary packaging, laboratories and other non-GMP areas which were not included in this initial scope.

CLIENT TESTIMONIAL

You always open our eyes to the savings opportunities that exist and how to go about implementing them. Thanks.

Client Senior Manager

Global top 10 pharmaceutical company

RESULTS

Energy savings identified (per year)

Energy savings identified (per year)

6,788,000 kWh

(11% site energy reduction)

Energy cost savings identified (per year)

Energy cost savings identified (per year)

$350,000 USD

Emissions reduction (per year)

Emissions reduction (per year)

2,311 tonnes

of CO2 emissions

The savings identified have an estimated overall payback period of less than 2 years.
A further $220,000 of annual savings are likely on the remaining HVAC systems not assessed.

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