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IDENTIFYING ENERGY AND WATER REDUCTION STRATEGIES AT A VACCINE MANUFACTURING FACILITY

Client: Global pharmaceutical manufacturer | Location: United Kingdom | Sector: BIOPHARMACEUTICAL MANUFACTURING

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PROJECT BRIEF

EECO2 were commissioned to examine, quantify and report on the opportunities for energy and water usage reduction at a UK vaccine manufacturing facility.

Key objectives included:

  • Identify and prioritise ‘quick win’ improvements that could be implemented immediately;
  • Identify, evaluate and prioritise significant energy and water improvement projects that could be implemented over the next 2-3 years (includes energy savings estimate and budget cost);
  • Engage with key site stakeholders (QA/Validation/Engineering) to develop the structured approach and documentation requirements to support proposed changes;
  • Transfer of knowledge to site on the risk based approach and current best practice for implementing energy reduction opportunities without compromising product quality;
  • Ensure output was action based with stakeholder agreed action plan, action owners and timelines.

METHODOLOGY

EECO2 delivered a full site energy and water focussed assessment – a proven process that guides the site team to identify and prioritise significant energy, carbon and water projects that have been discussed in detail and are viable for implementation.

This assessment was supported by detailed data analysis undertaken by EECO2 off site prior to the workshop. The off-site analysis involved creating a bespoke site energy and water model which was then verified during the site visit. This enabled the EECO2 team to rapidly identify and quantify realistic energy and water reduction opportunities on a whole site basis, to a tolerance of +/-30% cost and savings.

SOLUTION

The data analysis, supplemented by on-site observations, showed that HVAC (air movement, heating, cooling & dehumidifying) was the largest user in terms of energy consumption at 55% of site energy consumption and cost. The main areas of opportunity identified were:

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

Fresh air optimisation

Demand based ventilation

BMS optimisation set point and deadband control

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

Steam systems optimisation

Chilling and refrigeration systems optimisation

Water usage reduction, reuse and recycling

The energy and water assessment involved key stakeholders from Engineering, Quality Assurance and Validation teams. Potential projects were presented, discussed in detail and risk mitigation was integrated into the project proposals.

CLIENT TESTIMONIAL

The added benefits for me were that the approach as well as generating new ideas looked at existing ideas onsite and helped to consolidate/challenge our understanding. Shared best practice and learning is structured in such a way that there is involvement not just from engineering but also quality, manufacturing etc so that there is buy in from an early stage.

Site EHS Manager

Global pharmaceutical manufacturer

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

4,283,000 kWh

23% reduction in site energy usage

Energy cost savings identified (per year):

Energy cost savings identified (per year):

£322,000

Water savings identified (per year):

Water savings identified (per year):

13,674 m3

52% reduction in site water consumption

The energy savings identified have an overall simple payback period of 2.4 years. The water savings have a 3.3 year simple payback period.The energy savings identified have an overall simple payback period of 2.4 years. The water savings have a 3.3 year simple payback period.

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