IDENTIFYING ENERGY AND WATER REDUCTION STRATEGIES AT A VACCINE MANUFACTURING FACILITY

Site: | Location: United Kingdom | Sector: Biopharmaceutical Manufacturing

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

METHODOLOGY

Key objectives included:

Identify and prioritise ‘quick win’ improvements that could be implemented immediately

Identify, evaluate and prioritise significant energy and water improvements that could be implemented over the next 2-3 years (includes energy savings estimate and budget costs)

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

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.

Results

Energy savings identified (per year):

4,283,000 kWh

23% reduction in site energy usage

Energy cost savings identified (per year):

£322,000

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.

"Excellent technical knowledge of energy efficiency opportunities and quality of deliverables."

Engineering Director

Global Pharmaceautical Manufacturer

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