Hello,



  • This field is for validation purposes and should be left unchanged.
EECO2 Privacy Policy

ENERGY EVENT AT API MANUFACTURING SITE IN INDIA

Site: | Location: India | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

As the specialist in pharmaceutical HVAC energy efficiency, EECO2 was selected to be part of this energy event; concentrating on the HVAC side of creating cost-effective plans to reduce energy consumption at the client site, whilst maintaining product quality, compliance & safety. Any identified projects were expected to be practical, realistic and implementable, considering site constraints, development plans and new investments.

METHODOLOGY

EECO2 worked with the site engineering team, providing specialised services based on the site HVAC systems. Energy maps were produced by analysing the data
provided by the site. The previous full year data was used to prepare the maps. These were split by uses and by buildings to identify significant energy uses and locations to focus on.
The teams worked extremely well together on site, having prepared information beforehand, the event was effective in producing multiple projects. The teams created implementation strategies for each project to encourage the site team to continue on and achieve the savings identified.

SOLUTION

The solutions below are based on 17 developed projects and 9 ‘Just do it’ projects for the site:

GMP HVAC Optimisation

HVAC Plant Maintenance

Motor Upgrades

Meter monitoring and targeting

Boiler Improvements

RESULTS

Annual energy savings identified:

Annual energy savings identified:

6,600 MWh

(24% site reduction)

Annual energy cost savings identified:

Annual energy cost savings identified:

£200k

(31% site reduction)

Annual CO2 savings identified:

Annual CO2 savings identified:

3650 tonnes

(26% reduction)

The savings identified have an overall simple payback period of 3 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

SUCCESSFUL ENERGY EVENT FOR GLOBAL TOP TEN PHARMACEUTICAL COMPANY – INDIA

Site: | Location: India | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

As the specialist in pharmaceutical HVAC energy efficiency, EECO2 was selected to be part of this energy event; concentrating on the HVAC side of creating cost-effective plans to reduce energy consumption at the client site, whilst maintaining product quality, compliance & safety.
Any identified projects were expected to be practical, realistic and implementable, considering site constraints, development plans and new investments.

METHODOLOGY

EECO2 worked with the site engineering team, providing specialised services based on the site HVAC systems. Energy maps were produced by analysing the data provided by the site. The previous full year data was used to prepare the maps. These were split by uses and by buildings to identify significant energy uses and locations to focus on.
The teams worked extremely well together on site, having prepared information beforehand, the event was effective in producing multiple projects. The teams created implementation strategies for each project to encourage the site team to continue on and achieve the savings identified.

SOLUTION

The solutions below are based on 39 developed projects and 106 ‘Just do it’ projects for the site:

Air Change Rate Reduction

Fresh Air Reduction

HVAC Setback

BMS Optimisation

Dehumidifier optimization

Cooling Systems Fan Control & Metering

RESULTS

Annual energy savings identified:

Annual energy savings identified:

119 GWh

26% site reduction

Annual energy cost savings identified:

Annual energy cost savings identified:

£2 Million

32% site reduction

Annual CO2 savings identified:

Annual CO2 savings identified:

5.3k tonnes

88% site reduction

The savings identified have an overall simple payback period of 2.3 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

GLOBAL PHARMACEUTICAL ENERGY REDUCTION PROGRAMME – MULTI SITE

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

Find out more

PROJECT BRIEF

After a successful trial in Sydney, Australia, our client went on to introduce a corporate carbon reduction programme, to be rolled out globally. EECO2 worked with a further 10 of the client’s key sites, in the United States (6 sites), China (2 sites), Japan, UK and Australia.

METHODOLOGY

The EECO2 team conducted the on-site energy and water reduction assessment workshop events, working together with the site engineering teams and other stakeholders. The scope included a review of opportunities in HVAC systems serving all areas, utility generation & distribution (steam, chilled water, cooling water, compressed air systems) and water systems.

SOLUTION

EECO2 recommended that the client’s focus should be on rapidly implementing HVAC & BMS optimisation opportunities as these have high cost reduction, short paybacks and excellent emissions reductions. As an example, since the event took place, one site implemented optimisation of controls on several HVAC systems, which delivered $190k annual savings with a simple payback of 6 months. As well as the larger energy projects, the events identified 143 ‘Just Do Its’, which are low or no cost actions that site teams can action immediately.

The identified savings based on 273 developed projects.

The average simple payback period for all projects in this case study is 3 years.

The final report to the client showed a total avoided cost of $50 Million per year is achievable by 2025.

The projects identified in this programme represent extremely good value investment opportunities to realise significant sustainability improvements, which will aid the client in meeting corporate targets.

CLIENT TESTIMONIAL

This was a fast-paced event, requiring a lot of pre-execution with data gathering, meeting organization, safety preparation, and multiple logistics concerns. EECO2 was very helpful in identifying and prioritizing critical data needed prior to the event. The team developed models prior to the workshop and were open to changing their models, to reflect learnings they gained during the workshop. Thank you!

USA Site Contract Coordinator

Global Pharmaceutical Manufacturer

RESULTS

Annual energy cost savings identified:

Annual energy cost savings identified:

$6.4 Million

25% reduction

Annual energy savings identified:

Annual energy savings identified:

107 GWh

22% reduction

Annual emissions reduction:

Annual emissions reduction:

18,600 tonnes CO2

Annual Water Savings (40 Projects): 47 Million Gallons (22% reduction)

Projects have an average simple payback period of 3 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

PHARMACEUTICAL ENERGY REDUCTION ASSESSMENT WORKSHOP IN INDIA

Site: | Location: India | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 was appointed to carry out a pharmaceutical energy reduction assessment workshop, which included a HVAC energy assessment and major capital project review.
The objectives of the workshop were to create a cost-effective plan to reduce energy consumption at the client site whilst maintaining product quality, compliance & safety. Any identified projects were expected to be practical, realistic and implementable, considering site constraints, development plans and new investments.

METHODOLOGY

EECO2 conducted an on-site HVAC projects and energy reduction Assessment Workshop event working together with the client site engineering team.

Phase 1: Data collection, analysis, energy trending and mapping
Phase 2: On site Assessment Workshop event
Phase 3: Final report preparation, review and action planning

Energy maps were produced by analysing the data provided by the site. The previous full year data was used to prepare the maps. These were split by uses and by buildings to identify significant energy uses and locations to focus on.

SOLUTION

The solutions below are based on 24 developed projects for the site:

Biomass Boiler

Fresh Air Pre-treatment

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

Condensing Economiser for Fuel Oil Boilers

New RO to treat waste streams

RESULTS

Annual energy savings identified:

Annual energy savings identified:

21.7 GWh

24% site reduction

Annual energy cost savings identified:

Annual energy cost savings identified:

$3.15 Million

40% site reduction

Annual CO2 savings identified

Annual CO2 savings identified

26,000 tonnes

51% site reduction

Annual water savings identified: 102,000 m3

The savings identified have an overall simple payback period of 1.8 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY SAVING PROJECT UTILISING MEMU MONITORING SYSTEM

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

Find out more

PROJECT BRIEF

EECO2 Ltd was appointed to carry out a detailed site survey on potential energy savings within the site HVAC systems. The client site wanted to address any unnecessary energy waste.
During the site survey EECO2 identified four AHU systems for potential savings. The survey revealed a number of energy reduction projects on the site AHUs, including airflow setback, demand control and VAV retrofit to laboratory fume cupboards.

METHODOLOGY

A MEMU was installed on one of the systems in order to obtain adequate baseline energy data to ultimately verify the effectiveness of the delivered solutions. From the initial reports it was identified that there was unnecessary cooling and then re-heating of the supply air. This was in addition to the potential savings already identified in the survey.

SOLUTION

The solution in this case would be to optimise the BMS controls to all four AHUs on site. This would introduce deadband control and eliminate simultaneous heating and cooling. From the data collected by the MEMU and the initial analysis by EECO2, the further potential energy savings were calculated.

RESULTS

Potential energy cost savings identified in addition to the energy saving projects:

Potential energy cost savings identified in addition to the energy saving projects:

£24,000 per year

The energy savings identified have an overall simple payback period of 2 months.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY SAVING PROJECT IN TURKEY UTILISING MEMU MONITORING

Site: | Location: Turkey | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 Ltd was appointed to carry out a detailed site survey on potential energy savings within the HVAC systems. The client site wanted to address any unnecessary energy waste.

METHODOLOGY

During the site survey EECO2 identified the largest energy consumers on site. The EECO2 team then fitted one of the larger HVAC systems with the MEMU in order to obtain a granular energy analysis. From the detailed reports, it was identified that the heating control valve had been bypassed, which resulted in continuous heating during the summer. It was also identified, that the dehumidification control was very inefficient in consuming unnecessary energy. The team carried out energy calculations, which confirmed their findings enabling them to engineer the solution.

SOLUTION

The client site were informed that they had a by-passed heating valve, allowing them to imediately fix this problem at no cost. The EECO2 team optimised the dehhumidification control loop on the BMS system. The changes they made enabled the site to reduce their energy consumption in this area. The changes were then rolled out across the entire client site on every HVAC system.

RESULTS

Energy cost savings identified on 1 AHU:

Energy cost savings identified on 1 AHU:

£12,000 per year

The energy savings identified have an overall simple payback period of 0.25 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

ENERGY AND WATER ASSESSMENT WORKSHOP IN AUSTRALIA

Site: | Location: Australia | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 was commissioned to perform energy and water assessments on a pharmaceutical manufacturing client site in Australia.
The objectives of the workshop were to create a cost-effective plan to reduce energy and water consumption at the site whilst maintaining product quality, compliance & safety.
The data analysis showed that HVAC (air movement, cooling & dehumidifying) and associated services were a large user in terms of energy consumption at 52% of site energy consumption and cost approximately Aus $1.5million/year to deliver the required environmental conditions.

METHODOLOGY

The team began with a data collection exercise, liaising with site team, followed by a desktop review and initial analysis. The next step was a visit to the client site in Australia. EECO2 facilitated an on-site energy and water reduction assessment workshop event, working together with the client site team.

SOLUTION

A total of 38 energy efficiency opportunities and 6 water reduction were developed, including the following solutions:

HVAC & BMS – Air Change Rate Reduction, Demand Control, Setback, BMS Optimisation

Chilled Water – Pumping Optimisation and Adiabatic Cooling

Steam Systems – Economisers, Hot Water Setpoint Optimisation & Insulation

Lighting – LED Upgrades

Solar PV

Water – Bypass RO Plant Softener, WFI Blowdown back to boiler & Stoppers arriving clean

CLIENT TESTIMONIAL

As always EECO2 identified significant areas of energy reduction opportunity that the site was not aware of. In addition to detailed quantification of the potential costs and savings, you identified internal organizational issues that would need to be overcome to deliver the improvements… nice work!

Senior Manager, Global Engineering

Global Pharmaceutical Manufacturer - Sterile Products

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

8,800 MWh

(26% reduction)

Water savings identified (per year):

Water savings identified (per year):

10,900 cubic metres

(14% reduction)

Total cost savings identified (per year):

Total cost savings identified (per year):

Aus$ 802,000

With an average simple payback period of 3.4 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

RECIRCULATION FEASIBILITY STUDY PROVIDING ENERGY REDUCTION OPPORTUNITIES AT API R&D FACILITY

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

Find out more

PROJECT BRIEF

Following identification of a potential project in the ESOS report, EECO2 Ltd was appointed to carry out a detailed feasibility study, for the recirculation of air from the exhaust system back to the supply air handling unit (AHU) at this API R&D facility. The AHU is 100% fresh air unit and therefore a significant energy consumer for both electricity and steam. The area had potential solvent release, so the solution needed to have appropriate safety and control measures.

METHODOLOGY

The scope of the detailed feasibility study was customised to suite the needs of the project, including; refined energy calculations, schematic design works coordinated with respect to a complicated plant area and most importantly, open discussions with site engineering, safety and quality teams on proposed solutions.

The outcome of the study identified a number of potential options to deliver reduced airflow (air change rate reduction) and partial recirculation linked to space sensors, allowing excess air during any emergency events.

SOLUTION

The report concluded that with a structured, risk-based approach, energy savings of £80,000 per year can be delivered, with a payback less than 2 years. API facilities have great potential for improving safety monitoring while achieving more efficient HVAC operation following a systematic risk-based approach to project development.

Air Change Rate Reduction

Partial Recirculation

Out of Hours Recirculation

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

964,000 kWh

Energy cost savings identified (per year):

Energy cost savings identified (per year):

£80,000

The energy savings identified have an overall simple payback period of less than 2 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

FEASIBILITY STUDY ON HVAC PROJECTS AT API SITE

Site: | Location: Ireland | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

A pharmaceutical client site that manufactures APIs in Ireland was developing an energy saving plan for the whole site, to reduce energy, carbon emissions and energy cost. The client engaged the EECO2 team to work up potential projects in more detail and also generate new ideas. EECO2 was commissioned to provide HVAC feasibility studies for energy reduction projects.

METHODOLOGY

The team began with a data collection exercise, liaising with site team, followed by a desktop review and initial analysis.

The next step was a visit to the client site, to get a physical understanding of the issues, constraints and client expectations. The site survey helped to discuss and establish the critical requirements of the projects.

After the site visit, the team performed more detailed calculations and provided the site with the feasibility report and proposed the developed energy efficiency projects solutions in some detail. This included estimated cost breakdowns to allow a decision on whether the site would like to proceed in each case.

SOLUTION

The solutions below were involved in the 5 major HVAC projects refined by the feasibility study:

Air Change Rate Reduction

AHU fan efficiency improvements

Variable air flow volume system

HVAC recommissioning to optimise system effectiveness

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

2,840 MWh

Energy cost savings identified (per year):

Energy cost savings identified (per year):

€174,000

The client site continues to work through and implement the suggested projects and aims to reach the savings predicted.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

ENERGY ASSESSMENT PROJECTS LEAD TO DELIVERED SAVINGS

Site: | Location: Ireland | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

The EECO2 team was tasked with conducting an energy assessment on a client site in Ireland. They were then to support the site with implementing the agreed energy efficiency projects, helping the site to not only reduce energy consumption and emissions but to record the savings too.

METHODOLOGY

Focusing on 7 areas of the site, the team conducted the energy assessment and produced a list of recommended energy efficiency projects and a predicted saving for each. Working together the site team and EECO2 went forward with the agreed projects.

SOLUTION

EECO2 supported the client site with risk assessments, FRS development & change control for each area. Projects included:

Rebalance to reduce air change rates

Setback, when not in production

Introducing demand-based control

Adding additional control sensors to mirror worst case QBMS locations

RESULTS

Energy savings delivered (per year):

Energy savings delivered (per year):

2.5 GWh

Energy cost savings delivered (per year):

Energy cost savings delivered (per year):

€178k

From the 5 energy efficiency projects undertaken on site, the results show that the projects significantly over-delivered, producing a great ROI.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

ENERGY AND WATER CONSUMPTION REDUCTION AT LARGE PHARMACEUTICAL SITE

Site: | Location: Delaware, USA | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 was appointed to create a cost-effective plan to reduce energy consumption at the client site, whilst maintaining product quality, compliance & safety.

The client wanted to meet corporate sustainability objectives and improve site cost competitiveness. So, the EECO2 team was brought in to help the client reduce site energy and water costs, consequently lowering emissions and their carbon footprint. The team focused on HVAC energy consumption & water consumption of the site, whilst including, pipework, steam traps, control systems, boilers and chillers into their consideration for energy efficiency projects.

METHODOLOGY

First, the team performed a GEMBA walk around the client site and learned that there were some excellent initiatives (industry best practice) already in place. After a further quality and validation review, the team were able to discuss the impact on site targets.

The team created 200 ideas. 26 of which were ‘just do its’, which means that they can be instantly put into place. 40 were investigations and 44 were evaluated projects which create a roadmap to achieve the 2020 site sustainability goals.

SOLUTION

Below are just some of the 44 evaluated projects:

Supply air temperature reset

Out of hours AHU switch-off

Reduce air change rates for non-operational areas

Implement non-production setback

Implement supply air reset strategy

Reduce pressurization in certain areas

RESULTS

Energy savings and cost savings identified (per year):

Energy savings and cost savings identified (per year):

9.5 GWh and $622,000

16% reduction and 24% reduction

Water savings identified (per year):

Water savings identified (per year):

5.14 million Gallons

24% reduction

Emissions reduction (per year):

Emissions reduction (per year):

3,562 t CO2

20% reduction

Average payback of 2.6 yrs.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

FULL ENERGY ASSESSMENT AT PHARMACEUTICAL MANUFACTURING SITE IN JAPAN

Site: | Location: Japan | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 was to provide the client with principle consultancy expertise to support an Energy Assessment with their GMS manufacturing chain. 

Along with the site team and the energy assessment team, EECO2 performed an energy assessment on the client site in Japan – focusing on HVAC improvements.

The client site has a real opportunity to deliver significant energy and cost savings over the next 5 years. Especially involving HVAC, as this is their largest saving opportunity. Any changes to the HVAC system must be done in a way that ensures no quality impact and so it is important to involve HVAC experts like EECO2.

METHODOLOGY

Focusing on the HVAC system on site, the EECO2 team completed the following:

Data collection & energy mapping
HVAC data collection & modelling
Energy Assessment support on client site

SOLUTION

There were 34 projects on the final project list, with 14 of them producing 80% of the savings. They included:

HVAC Optimisations (All site)

Optimise Chiller Control and Setpoint of Chilled Water Temperature

LED Upgrades

BMS Optimisation

Dehum Reactivation Heat Recovery (10 Units)

Improve Condensate Recovery

EC Fan Trials

Switch Off Plan for Production, Offices, Labs, Comp Air Supplies

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

4,130 MWh

30% site reduction

Energy cost savings identified (per year):

Energy cost savings identified (per year):

38 Million Yen

31% site reduction

Emissions reduction identified (per year):

Emissions reduction identified (per year):

1,427 tCO2

of CO2 emissions

The savings identified have an overall simple payback period of 3.2 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

PHARMACEUTICAL ENERGY REDUCTION ASSESSMENT WORKSHOP

Site: | Location: Philadelphia, USA | Sector: Consumer Health Products

Find out more

PROJECT BRIEF

This was a pharmaceutical energy reduction assessment workshop including HVAC energy assessment and major capital project review. The client site facility mostly manufactures and packs non-sterile consumer healthcare products.

The objectives of the workshop were to create a cost-effective plan to reduce energy consumption at the client site whilst maintaining product quality, compliance & safety. Any identified projects were expected to be practical, realistic and implementable, considering site constraints, development plans and new investments. The site had four major capital projects in the pipeline which were assessed as part of the energy workshop. This will reduce emissions, carbon footprint and utility costs to meet the corporate sustainability objectives and improve site cost competitiveness.

METHODOLOGY

EECO2 facilitated an on-site HVAC projects and energy reduction Assessment Workshop event working together with the client site engineering team and other stakeholders.

Phase 1: Data collection, analysis, energy trending and mapping.
Phase 2: On site Assessment Workshop event.
Phase 3: Final report preparation, review and action planning.

Energy maps were produced by analysing the data provided by the site. The previous full year data was used to prepare the maps. These were split by uses and by buildings to identify significant energy uses and locations to focus on.

The assessment workshop event is a structured 4-day, facilitated workshop drawing on the local site expertise and knowledge, with external current best practice and challenge of current practices being provided by the EECO2 facilitation team. It also included peer review workshops with other local designers and consultants to assess and maximise opportunities of planned capital projects.

SOLUTION

The solutions below are based on 16 developed projects for the site:

Air change reduction

Fresh Air reduction and dehumidification

HVAC Setback

BAS Optimisation

EC Fans

Capital project design review

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

12.4 GWh

18% reduction of site totals

Energy cost savings identified (per year):

Energy cost savings identified (per year):

$490,000

19% reduction of site totals

The savings identified have an overall simple payback period of 2.5 years and provided a strategy to deliver existing capital projects with minimum investment and maximum return.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

UNIVERSITY LABS ENERGY AND EMISSIONS REDUCTION PROJECT

Site: | Location: United Kingdom | Sector: Research & Development Labs

Find out more

PROJECT BRIEF

The sustainability team of the University were under pressure to reach carbon dioxide reduction targets. They were aware that their laboratory buildings were the largest users of energy and in particular the synthetic chemistry building and its ventilation system. The building contains a large amount of fume cupboards, so safety was a prime concern during the project for both the University and EECO2.

The brief for the EECO2 team was to address carbon dioxide reduction within the building and provide solutions for the sustainability team to help reach their targets, whilst working very closely with the University Estates Team and the users of the building, as to not disrupt the ongoing work within the building.

METHODOLOGY

Firstly, the team assessed the safety requirements of the building during a fume cupboard survey. They then performed a HVAC survey to assess opportunities for improvements, again evaluating safety requirements of the building. The survey uncovered a satisfactory HVAC design, however there had been modifications made to the design and components that had failed, resulting in lower efficiency levels than the original design is able to deliver. Using the survey results, the EECO2 team produced safety and energy efficiency suggestions and created an implementation plan. The University’s sustainability team then hired EECO2 to implement the plan. There were issues along the way, which the team overcame, for example, there were concealed holes in the duct work, causing pressurisation issues. The team found and repaired the hidden cavities in addition to the scheduled repairs.

SOLUTION

The repairs had to be organised with the University in mind. The EECO2 team had to be very flexible, often working out of hours, ensuring the fume cupboards were free for use when required, reducing the impact on the building users as much as possible.

EECO2 performed extensive testing to develop a revised exhausted fan control strategy, to ensure safe velocities were maintained in the air duct

Repairs, modification and recommissioning of the HVAC system, including the controls and the components

EECO2 did such a good job for the sustainability team, that they have been asked to assess a number of additional buildings on the University campus too.

RESULTS

Electrical Energy savings identified (per year):

Electrical Energy savings identified (per year):

30% reduction

in electrical energy consumption for the building

Electrical Energy cost savings identified (per year):

Electrical Energy cost savings identified (per year):

£78k

annual electrical energy cost savings

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

WATER REDUCTION STRATEGY DEVELOPED TO AID WATER SCARCITY IN REGION

Site: | Location: Cape Town | Sector: High Tech Industries

Find out more

PROJECT BRIEF

EECO2 was tasked with developing a strategy to reduce water usage at the busy Cape Town site. As the water supply was at a critical level in the area, heading into summertime with a low winter rainfall, the situation was looking dire. While limits were imposed, they were not being adhered to and so the condition was worsening.

METHODOLOGY

Using best practiced expertise, the EECO2 team investigated opportunities to find any leaks and fix them, reduce any unnecessary usage of water, reuse and recycle if possible. Looking at the current water usage in production and what procedures were in place, the team worked on what process could be put into place to reduce the use of water on a daily basis and how much of this could be reused.

The team also looked at how to communicate the situation to the workforce and instill the urgency of the situation to reduce consumption and waste.

Working with an extremely interactive and engaged team who contributed immensely throughout the week, allowed the event to run smoothly with great end results.

SOLUTION

Creating a Water Strategy for the site, with key focus areas of water recovery, cooling systems, RO plants, rain water & domestic, which included:

Water metering – adding to and modifying existing metering, including the creation of a KPI strategy to create alert limits

Raising awareness of the situation daily

New procedures in place for leak reporting

Replace water-cooled, with air-cooled chillers

Recycling water where possible from waste streams i.e. reuse final CIP rinse for first rinse of next cycle

Recover HVAC condensate for re-use

Rainwater harvesting

Sharing best practice water reduction with other sites

In the end, the team developed 24 projects on the final project list, with a number of ‘just-do-it’ projects which will deliver immediate savings if implemented.

RESULTS

Water savings identified (per year):

Water savings identified (per year):

47%

Water savings potential identified from projects

Water savings identified (per year):

Water savings identified (per year):

16%

Water savings from rain water harvesting

Water cost savings identified (per year):

Water cost savings identified (per year):

ZAR 562k

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

ENERGY REDUCTION OPPORTUNITIES FROM AN ENERGY ASSESSMENT LEAD TO REAL SAVINGS

Site: | Location: Ireland | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 facilitated an on-site energy reduction event for a Global pharmaceutical manufacturer client, working together with the client engineering team and other stakeholders. The energy reduction workshop is a proven process that guides the site team to identify and prioritise significant energy and carbon reduction projects that are accepted and can be implemented.

The workshop is supported by detailed data analysis that the EECO2 team undertake off site prior to the workshop. The off-site analysis involves creating a site energy model, bespoke to this client, which is then verified during the workshop.

This enables the EECO2 team to rapidly identify and quantify realistic energy reduction opportunities on a whole site basis.

METHODOLOGY

EECO2 delivered an HVAC energy focussed assessment – 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 site had previously identified key areas of focus and so the scope of investigation included and added to the known opportunities. EECO2’s assessment was focused on GMP areas and identified opportunities for significant savings. During the week, the enthusiastic site team along with EECO2’s engineers combined all identified opportunities into a coherent complete plan for the site to execute.

SOLUTION

The data analysis showed that HVAC systems (moving, heating, cooling & dehumidifying air) consume approx. 70% of the current total site energy. These systems generally operate continuously to provide the required environmental conditions. The main areas of opportunity identified were:

Further Integration of existing metering, monitoring & targeting to drive energy performance actions and verify implementation benefits

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

ISO 8 HVAC areas would benefit from variable air volume supply controlled on temperature rather than a fixed air supply rate

Chilled water system efficiency improvements

Long-term strategy to meet aggressive energy and carbon reduction targets

After the event, EECO2 worked closely with the site to develop project details for the final report. The site team took the findings and actively pursued the air change reduction projects to deliver a great savings result. With an ISO50001 Energy Management System in place, the site could easily track their energy consumption before and after, demonstrating the success of the projects.

RESULTS

Actual annual energy savings delivered:

Actual annual energy savings delivered:

846,100 kWh

Actual annual energy cost savings delivered:

Actual annual energy cost savings delivered:

€56,460

Actual annual emission savings delivered:

Actual annual emission savings delivered:

418 tonnes

of CO2 emissions

The event identified savings of 1,500 MWh, €122k and 655 tonnes of CO2. The site’s commitment to project delivery has been a great success, but there is still more to deliver. EECO2 would be pleased to support the realisation of the remaining opportunity. The savings identified have a 0.9 year payback period.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY SAVING PROJECTS, IDENTIFIED THROUGH ESOS AUDIT

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

Find out more

PROJECT BRIEF

EECO2 performed an ESOS audit, feasibility study and completed energy saving projects on a client site, which focussed on the buildings HVAC systems.

The Energy Savings Opportunity Scheme (ESOS) is the UK’s response to Article 8 of the European Commission’s Energy Efficiency Directive. It is a mandatory energy assessment scheme for organisations in the UK that meet the qualification criteria. The aim is to cut carbon emissions, by requiring large businesses to identify energy reduction measures and make energy savings. ESOS assessments are audits of the energy used by their buildings, industrial processes and transport to identify cost-effective energy saving measures.

METHODOLOGY

The journey began with EECO2 performing an ESOS Energy Audit at the customer site. This provided a list of potential projects which would improve energy efficiency on the site.

EECO2 were then commissioned to perform a feasibility study, which showed the solutions and potential savings were feasible and could go forward and be implemented.

EECO2 focussed on the energy consumption within the warehouse and production buildings and so they were fitted with sensors to allow EECO2 to monitor the energy usage through a Mobile Energy Monitoring Unit (MEMU).

The MEMU is a unique metering solution, specifically developed to monitor the energy performance of pharmaceutical HVAC systems. It enables clients to view energy consumption and costs of individual HVAC systems on a real-time basis. The system enables a detailed view of heating, cooling and fan power energy consumption.

The agreed projects were implemented in order to reduce energy consumption, whilst maintaining quality, safety and regulatory requirements.

After the implementation of the projects, EECO2 measured the actual data of consumption via the MEMU and were able to calculate the amazing results that showed exactly what the EECO2 projects had achieved so far for the site.

SOLUTION

EECO2 completed an outline scheme design, engineering & commercial feasibility study that determined a more accurate cost and saving estimate to implement demand-based ventilation schemes in the warehouse and production buildings.

Warehouse – AHUs 1 & 2 fan utilisation and out-of-hours airflow setback

Warehouse – AHU 3 essential repairs and out-of-hours setback function

Production – temperature demand-controlled ventilation and out-of-hours setback

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

2.5 MWh

17% reduction in site energy consumption

Energy cost savings identified (per year):

Energy cost savings identified (per year):

£ 180,000

15% reduction in site energy costs

Emissions reduction (per year):

Emissions reduction (per year):

720 tonnes

of CO2

The project had a simple payback period of 0.8 years

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY AUDIT FOR R&D FACILITY AND IMPLEMENTATION PLAN

Site: | Location: Philadelphia, USA | Sector: Research & Development Labs

Find out more

PROJECT BRIEF

EECO2 was appointed to perform a HVAC energy audit and deliver a prioritised implementation plan for a large R&D facility located in Philadelphia. This was to allow the client to allocate budgets and resources to meet a phased implementation plan for the next 3 years in order to deliver the benefits identified.

METHODOLOGY

The audit focus was to identify energy saving opportunities for the site HVAC systems that serve the extensive R&D laboratory facilities ensuring compliance with EHS best practices. The identified opportunities were prioritised based on site impact, costs and benefits and were then presented to the client with an implementation plan.

SOLUTION

The main solutions that EECO2 identified were in the following areas:

Air change reduction

HVAC Set Back / OFF

Fresh Air reduction

BAS Optimisation

EF Motors & VSD’s

High Efficiency Filtration

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

30,995MWh

Energy cost savings identified (per year):

Energy cost savings identified (per year):

$1,459,000

22% reduction in site energy costs

Emissions reduction (per year):

Emissions reduction (per year):

11,304 tonnes

of carbon emissions

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

ENERGY SAVING OPPORTUNITIES IN LIFE SCIENCE FACILITIES

Site: | Location: Kenya | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 specialises in identifying and delivering energy savings in highly regulated environments for global businesses desiring to reduce energy consumption, cost & carbon footprint.  EECO2 supported this Top 10 Pharmaceutical Manufacturer in delivering Global Energy Reduction Projects.

METHODOLOGY

EECO2 provided engineering, validation & project management support for the following stages of project delivery:

1. Detail survey & scheme design for trial HVAC project HVAC

2. Feasibility design for ACPH, FA and pressure regime schemes

3. Production of functional requirement specifications & change control documentation. Interface with QA, engineering & production

4. Details design & PM support

5. Delivery trial projects & full turnkey delivery (utilising local expertise)

SOLUTION

HVAC Proposed Saving Opportunity - Key Points of Study:

Air Volume Reduction (Maintaining Compliance & heat load removal)

Reducing fresh air volumes to minimum for pressure and occupants & GMP

BMS Optimisation

Night Set-Back and Shut Down strategy of HVAC systems

High Efficiency Motors

Fan Upgrades

Filtration – low energy filters / excessive filtration

Maintenance issues commonly found in HVAC plants

Cooling & Heating Systems Optimisation

Facility GMP Risk Assessments

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

478,072 kWh

Energy cost savings identified (per year):

Energy cost savings identified (per year):

8,667,436 KES

21% reduction in site energy costs

Emissions reduction (per year):

Emissions reduction (per year):

182 tonnes

of CO2 emissions

EECO2 will support the site going forward, as required, for HVAC & BMS development.
EECO2 have developed bespoke monitoring & measuring systems (MEMU) to support & measure delivered energy savings.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

LABORATORY OPTIMISATION AND UPGRADES FOR ENERGY EFFICIENCY

Site: | Location: Singapore | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 was tasked to reduce energy demand at the client site, without compromising on compliance or laboratory safety.
The client site had very high energy demands, driven by original HVAC design and layout with high air change rates and fresh air volumes.

METHODOLOGY

EECO2 supported with a HVAC design review, defined project scope, managed local contractors.

EECO2 carried out the smoke visualisation trials and recommended a reduced fume cupboard capture face velocity, to deliver 20% energy savings.

The client then used this data to develop strategy for further improvement work.

SOLUTION

The main opportunities solutions for optimisation identified were as follows:

Reduce existing air change rates

Reduce existing fresh air volume

Improve plant operational maintenance

Optimise BMS system

Recommended upgrading laboratory fume cupboards to VAV

Recommended upgrade & control of warehousing facilities

RESULTS

Energy savings identified (per year):

Energy savings identified (per year):

2,200 MWh

Energy cost savings identified (per year):

Energy cost savings identified (per year):

$347,000

Emissions reduction (per year):

Emissions reduction (per year):

985 tonnes

of carbon emissions

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

REDUCING FUME CUPBOARD ENERGY USAGE IN R&D CHEMISTRY LABORATORIES

Site: | Location: United Kingdom | Sector: Research & Development Labs

Find out more

PROJECT BRIEF

Our client was experiencing high energy demand driven by high volumes of treated fresh air to a large number of fume cupboards operating 24/7.

METHODOLOGY

We were tasked with targeting fume cupboard capture face velocity (CFV) reduction and introducing night setback in order to reduce energy demand without compromising on laboratory personnel safety.

SOLUTION

We carried out the following:

Produced a detailed smoke trial approach document for client approval

Proved the feasibility of reducing CFV by carrying out a smoke visualisation trial

Produced a bespoke smoke trial video matrix to simplify video analysis of trial

Recommended replacement of existing laboratory supply air diffusers

Demonstrated capability to safely reduce existing CFV’s to level agreed with EHS / users

Developed diversity and night setback strategy for client review

Complete risk assessments, change and regulatory documentation

CLIENT TESTIMONIAL

The EECO2 team demonstrated a thorough understanding of laboratory air systems. The data obtained was instrumental in formulating our energy reduction strategy… also their flexibility (weekend working) was appreciated.

Site Facilities Manager

Global pharmaceutical manufacturer

RESULTS

Energy savings delivered (per year)

Energy savings delivered (per year)

293,000 kWh

Energy cost savings (per year)

Energy cost savings (per year)

£12,000

Emissions reduction (per year)

Emissions reduction (per year)

75.4 tonnes

of CO2

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

COLLABORATIVE STUDY ON IMPACT OF REDUCING ROOM AIR CHANGE RATES ON CLEANROOM CLEANLINESS

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

Find out more

PROJECT BRIEF

The HVAC energy demand of classified cleanrooms has only recently come into focus, yet electrical and heat energy used to condition, supply, filter and remove the air typically equates to 50-75% of a facility’s total energy costs. 

Prior to this study, there had been limited scrutiny of air change and air velocity requirements when experience shows cleanrooms are operating far and above the levels required for regulatory compliance.

METHODOLOGY

The aim of the project was to identify by scientifically based experiments, the impact of reducing room air change rates and unidirectional airflow on cleanroom cleanliness. The prime objective was to identify optimum settings to safely reduce HVAC energy demand without compromising on product safety, quality and regulatory compliance.

In order to carry out this study, we first established collaboration between three highly influential pharmaceutical companies to set a precedent for the industry. Real cleanroom operations were carried out throughout the experiment so operators were recruited, trained and validated in cleanroom gowning and cleanroom etiquette.

SOLUTION

Once the pre-designed experiments had been carried out and the data collated, we then carried out a full data review and determined the key findings.

The final report document and data was presented for peer review (ISPE)

CLIENT TESTIMONIAL

The findings of this novel study have huge implications for the industry and have added significantly to the knowledge base.

3 global pharmaceutical companies

RESULTS

Energy cost savings identified (per year)

Energy cost savings identified (per year)

£15,500,000

Emissions reduction (per year)

Emissions reduction (per year)

118,000 tonnes

of CO2

Further energy savings (reduced capital spend on new build)

Further energy savings (reduced capital spend on new build)

£400,000

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY REDUCTION IN EFFERVESCENCE MANUFACTURING AREA

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

Find out more

PROJECT BRIEF

Our client had an issue with very high energy demand driven by the original HVAC system design which was also unable to meet product critical relative humidity conditions during summer months.

SOLUTION

Following a detailed review of the HVAC and BMS systems, we implemented the following:

Reduce existing air change rates

Reduce existing fresh air volume

Install new VSD’s to the supply air fans

Replace the existing supply air diffusers to improve air distribution

Re-commission and balance the complete manufacturing areas HVAC system

Supported upgrade of BMS system, installation of VSD’s

Maintenance upgrade of filtration and control valve replacement

Completed product risk assessments, Engineering Change Control documentation and all required regulatory documentation covering the changes

CLIENT TESTIMONIAL

The savings delivered during phase 1 have exceeded our expectations and the quality team have supported the risk based approach used to deliver the savings. We now have to move on to phase 2 upgrade which is much more demanding but the confidence and structure knowledge we gained during phase 1 will help us deliver our target for the year.

Global pharmaceutical company

RESULTS

Energy savings delivered (per year)

Energy savings delivered (per year)

1,500 mWh

Energy cost savings (per year)

Energy cost savings (per year)

£58,000

Emissions reduction (per year)

Emissions reduction (per year)

686 tonnes

of CO2

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY FOCUSSED ASSESSMENT OF AN ASEPTIC PHARMACEUTICAL MANUFACTURING SITE

Site: | Location: Italy | Sector: Pharmaceutical Manufacturing

Find out more

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.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

IDENTIFYING ENERGY AND WATER REDUCTION STRATEGIES AT A VACCINE MANUFACTURING FACILITY

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

Find out more

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 identifying and prioritising ‘quick win’ improvements that could be implemented immediately.

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.

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.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

SITE MASTER PLANNING FOR SUSTAINABILITY

Site: | Location: South East Asia | Sector: Biopharmaceutical Manufacturing

Find out more

PROJECT BRIEF

Our client was planning to build a new manufacturing facility in Asia and requested a complete review of the concept design with evaluated options to optimise the energy performance of the facility.
EECO2 provided a report, focused in detail on the HVAC system, but also addressing related engineering and utility services for the facility.

SOLUTION

Review of existing scheme to provide a recommendation for a more sustainable approach to building services including HVAC systems:

GMP qualification principles

Building design principles including loads

GMP & non GMP areas

Building controls, cooling, heating and dehumidification systems

Opportunities for heat recovery and renewables

Low energy ventilation including: filters, motors, fans and laboratories

Enhanced / integrated renewable strategies

Metering and monitoring strategy for future energy control

A building energy simulation model was created to evaluate design options on life cycle costs and energy consumption and included modelling of variations in building fabric and construction standards, air change rates and specific fan power

The focus of detail in the report is on the HVAC. However, there is some discussion and recommendations made for best practices on other utility systems including refrigeration, compressed air and dust collection.

RESULTS

Energy savings

Energy savings

60%

From design optimisation

Energy savings

Energy savings

74%

From design plus HVAC optimisation

A 74% energy reduction was found to be achievable through risk based approach to air change rates and incorporating high efficiency air handling plant, refrigeration plant and renewable heating technologies.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY REDUCTION IN A PHARMACEUTICAL WAREHOUSE

Site: | Location: USA | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

Our brief was to reduce energy demand without compromising on quality or compliance.

SOLUTION

Following a detailed review of the HVAC system, we implemented the following:

Reduce existing air change rates.

Reduce existing fresh air volume.

Install new VSD’s to the 100kW supply air fans.

Replace the existing supply air diffusers to improve air distribution.

Use existing warehouse HVAC system to serve retained samples store.

Risk based approach to mitigate potential “out of condition” impact.

As well as supporting the HVAC design review, EECO2 also scoped the project before local contractors bid to complete the implementation phase.

CLIENT TESTIMONIAL

This project was key for delivering the site’s annual energy target. It exemplifies how the proper air flow and fresh air can contribute significant energy savings. This type of project will be replicated in the remaining areas of our facility.

Site Utilities Manager

Global pharmaceutical company

RESULTS

Energy savings delivered (per year)

Energy savings delivered (per year)

1,950 mWh

Energy cost savings (per year)

Energy cost savings (per year)

$135,000

Emissions reduction (per year)

Emissions reduction (per year)

917 tonnes

of CO2

The project had a simple payback period of less than 2 years.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC ENERGY SAVINGS DELIVERED BY OPTIMISATION OF A DEHUMIDIFICATION SYSTEM

Site: | Location: Japan | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

The site was selected as the key installation base for the Japan off the grid sustainability initiative, with the target of the pharmaceutical manufacturer’s operations in Japan being carbon neutral.
In order to progress the energy reduction programme a HVAC pilot project was identified with the following objectives:
  • Reduce HVAC energy consumption without adverse impact on product quality or safety.
  • Modify the production area air handling units plus the associated fresh air treatment AHUs during summer shutdown.
  • Ensure that the savings identified were both viable and deliverable.
  • Upskill site team to self-deliver further energy reductions in the future.

METHODOLOGY

Most of the HVAC systems in the OSD area had been designed to deliver air with very low relative humidity (RH) (less than 35% RH). The products currently being manufactured required air to be delivered at less than 60% RH.
The HVAC system required modification and rebalancing in order to meet current manufacturing requirements, without impacting on product quality or manufacturing output.
A product quality risk assessment was developed with the site quality, production and engineering teams. The potential risks were therefore mitigated and incorporated into the design and commissioning procedures.

SOLUTION

Work included:

The desiccant dehumidifier on the fresh air serving the OSD Area was fitted with an automated bypass, allowing it to be switched off but still allowing use when required via the building management system (BMS).

The BMS itself was modified in line with the requirements of the revised BMS FDS that was prepared for the project. If a future product requires different humidity conditions then the parameters in the control system can be changed accordingly.

The airflows were re-balanced in-line with the current regulatory guidelines.

RESULTS

Energy savings delivered (per year)

Energy savings delivered (per year)

1,165,336 kWh

Energy cost savings identified (per year)

Energy cost savings identified (per year)

£57,000

Emissions reduction (per year)

Emissions reduction (per year)

233 tonnes

of CO2

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

TABLET MANUFACTURING SUITE HEATING, VENTILATION AND AIR CONDITIONING SYSTEM UPGRADE

Site: | Location: Cape Town | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 was asked to assist in reducing energy demand at a tablet manufacturing facility without compromising product quality or regulatory compliance. Challenges included:
  • High volumes of fresh air requiring dehumidification in very challenging ambient conditions
  • Adapting the HVAC system to meet current manufacturing requirements
  • Reducing the volume of the dust extraction system and install VSD
  • Initiating no operational setbacks.

SOLUTION

Our work included:

Install a fresh air cooling coil to eliminate dehumidification within the air handling unit (AHU)

Rebalance the areas dust extraction system to eliminate nozzles no longer required

Install a VSD onto the dust extraction unit to maintain pipework carrier velocity consequently enabling a reduced fresh air volume

Rebalance the Air Change Rates to reflect area manufacturing change of use.

Initiate non-operational air volume reductions.

Optimise BMS system.

Product risk assessments were developed with the site QA, production & engineering team.

Risk mitigation was evaluated and included where required.

Final design changes reflected a risk averse approach.

CLIENT TESTIMONIAL

It’s going to be a tough year and to know that we have such a good team supporting some of these changes makes the job a lot easier.

Manufacturing Support Manager

Global pharmaceutical manufacturer

RESULTS

Energy savings (per year)

Energy savings (per year)

363,000 kWh

Energy cost savings (per year)

Energy cost savings (per year)

£36,000

Emissions reduction (per year)

Emissions reduction (per year)

336 tonnes

of CO2

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

HVAC CONTROLS OPTIMISATION AT PHARMACEUTICAL MANUFACTURING FACILITY

Site: | Location: Puerto Rico | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

EECO2 identified, following initial energy reviews carried out across both manufacturing sites, that the heating, ventilation and air conditioning (HVAC) and building management system (BMS) were not operating optimally and that efficiency improvements could be realised.
While the HVAC systems were delivering compliant facility temperature and humidity control, the systems were delivering this at an energy expense with failed equipment.
In addition to the energy cost, it was suspected that control devices and readings within the BMS may have been from faulty sensors and valves, often leading to manual interventions to the systems which can reduce the ability of the system to respond efficiently to environmental conditions, both internally and externally.
Our brief therefore included the identification and implementation of remediation work to correct and clear any underlying faults.

METHODOLOGY

The initial step was to identify the necessary actions and develop a plan for enabling remediation work by local contractors.
Where it was verified that mechanical and electrical functionality was correct, the control logic was checked to ensure it matched the needs of the space. Other steps followed to optimise the controls as time allowed, however the focus was on returning as many systems as possible to a stable, automatic operation. The process for identification and remediation of issues was broadly as follows:

  • Check mechanical/electrical functionality
  • Verify control logic is efficient and compliant, modify logic appropriately
  • Check time scheduling setup appropriately
  • Apply deadbands/offsets to temp and humidity
  • Tune control loops to provide robust response
  • Maintain optimum performance – monitor ongoing performance.

SOLUTION

BMS optimisation was achieved via the following:

EECO2 developed the Quality Risk Assessment documentation and worked with the client Quality team to gain approval

Fixing defective mechanical equipment and sensor issues – routine maintenance activity following existing SOP’s

Changing filters and fan belts where required – routine maintenance activity following existing SOP’s

Checking software logic and compliance with original specification and current site requirements

Modifying software logic as required to deliver a more optimised control strategy

EECO2 also monitored system stability and performance pre and post project implementation.

RESULTS

Energy savings identified (per year)

Energy savings identified (per year)

5,847,000 KWH

Energy cost savings identified (per year)

Energy cost savings identified (per year)

$900,000 USD

Emissions reduction (per year)

Emissions reduction (per year)

2,602 tonnes

of CO2

The project defined 3 primary success criteria which were deemed to have been met:
• Improved temperature and humidity control
• Reduced energy consumption
• Improved HVAC system compliance and robustness.
In addition, as the project was delivered while both sites were working live it was imperative that conditions were maintained within quality compliance limits at all times. This objective was met with zero quality compliance environmental excursions.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

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

Site: | Location: Australia | Sector: Pharmaceutical Manufacturing

Find out more

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.

CLIENT TESTIMONIAL

This project delivered 30% of the site’s annual carbon reduction target.

Client

Sterile pharmaceutical manufacturer

RESULTS

Energy savings identified (per year)

Energy savings identified (per year)

455,000 kWh

Energy cost savings identified (per year)

Energy cost savings identified (per year)

$63,000 USD

Emissions reduction (per year)

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.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

COMFORT AND ENERGY IMPROVEMENTS AT A POWDERED BEVERAGE MANUFACTURING SITE

Site: | Location: India | Sector: Consumer Health Products

Find out more

PROJECT BRIEF

Our client was experiencing high HVAC energy demand driven by the original system design in order to meet product critical relative humidity conditions during summer months. Forecast energy cost rises of 17% per year were putting increased pressure on budgets.
The brief was to reduce the dehumidification energy demand without compromising operator working conditions and product quality.

METHODOLOGY

EECO2 worked with the site team as part of an Energy Kaizen event to understand the problem in detail.

SOLUTION

This approach led to key recommendations to improve workplace conditions in addition to energy reduction opportunities, as highlighted below:

Achieve dehumidification with chilled water coil as opposed to desiccant wheel with steam recharge, avoiding significant replacement capital costs.

Rebalance HVAC system and reduce air change rates in spreading, scraping and grinding areas.

Reconfigure airflow and pressurisation regime, using existing plant, to reduce working temperatures in rack cooling areas.

Improved filtration strategy to reduce pressure drop and fan energy consumption.

CLIENT TESTIMONIAL

Given the significant anticipated cost rises in energy (forecasted at 17% a year, for the next 3 years) and our projected increase in manufacturing capacity, we must do everything we can to reduce our energy costs.

Site Energy Manager

Global consumer beverage manufacturer

RESULTS

Energy savings (per year)

Energy savings (per year)

591,000 kWh

Energy cost savings (per year)

Energy cost savings (per year)

Rs 2.1m

Emissions reduction (per year)

Emissions reduction (per year)

350 tonnes

of CO2

The project had a simple payback period of less than 2 years and also resulted in improved working conditions whilst avoiding capital cost.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

LABORATORY AIR SYSTEM RETROFIT

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

Find out more

PROJECT BRIEF

Our client had old HVAC plant serving a very large number of constant air volume (CAV) face and bypass fume cupboards which was consuming significant energy.
The brief was to reduce energy demand without compromising on operator safety.

METHODOLOGY

Following a detailed review of the HVAC system, we implemented the following:

SOLUTION

In addition to upgrading the supply units with control and filtration upgrades, we implemented:

Retrofit Variable Air Volume (VAV) to the existing fume cupboards.

Install pressure controllers to each laboratory.

Initiate fume cupboard diversity into each laboratory.

Remove individual booster fans and upgrade secondary fans with VSD’s.

Installation of energy monitoring units to verify savings and act as MM&T capability.

CLIENT TESTIMONIAL

A monthly (usage) figure of around 120 mWh has reduced to around 70 mWh, which is a very significant reduction. When we also compared total use for the whole Wilton Centre, we see reductions of 9.5%. It is our intention to now carry out similar modifications in D, N, & E Blocks.

Site Utilities Manager

Wilton Centre

RESULTS

Energy savings delivered (per year)

Energy savings delivered (per year)

363,000 kWh

Energy cost savings (per year)

Energy cost savings (per year)

£235,000

Emissions reduction (per year)

Emissions reduction (per year)

1,700 tonnes

of CO2

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

IDENTIFYING HVAC ENERGY REDUCTION STRATEGIES AT A PHARMACEUTICAL MANUFACTURING FACILITY

Site: | Location: China | Sector: Consumer Health Products

Find out more

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.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

IDENTIFYING HVAC ENERGY REDUCTION STRATEGIES FOR AN ORAL SOLID DOSE PHARMACEUTICAL MANUFACTURING FACILITY

Site: | Location: China | Sector: Pharmaceutical Manufacturing

Find out more

PROJECT BRIEF

To identify HVAC energy reduction strategies throughout various manufacturing spaces and laboratories 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. EECO2 analysed this data to determine the likely opportunities for efficiency improvements in each process area. During the site survey, potential opportunities were assessed on 80% of the HVAC systems. 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:

Switch off fume cupboards out of hours, with appropriate controls in place.

Switch off or reduce air change rates of HVAC units in areas not currently used for production.

Rebalance air distribution systems to minimise extract whilst providing sufficient outside air for dust extractor and leakage to maintain pressurisation.

Install bypass to dehumidifiers in liquids area and raise humidity setpoint within compliance limits.

Improve door sealing and fabric to reduce air leakage.

We also recommended a practical implementation plan which would ensure that changes can be made safely and efficiently whilst maintaining quality and compliance. The plan was agreed in principle with all stakeholders, including Quality Assurance and Validation groups. Much of the implementation can be delivered by the local site team, supplemented by EECO2 technical and project management expertise when requested.

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):

4,564,000 kWh

(4,564 MWh)

Energy cost savings identified (per year):

Energy cost savings identified (per year):

$377,000 USD

Emissions reduction (per year):

Emissions reduction (per year):

2,065 tonnes

of CO2 emissions

The savings identified have an estimated overall payback period of less than 2 years. A further $150,000 of annual savings are likely on the remaining HVAC systems not assessed.

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch

TRIALS TO SAFELY REDUCE ENERGY CONSUMPTION OF FUME CUPBOARDS USING C-FOILS

Site: | Location: United Kingdom | Sector: Research & Development Labs

Find out more

PROJECT BRIEF

By improving the containment of a fume cupboard you can safely reduce the capture face velocity (CFV) subsequently reducing its energy consumption and operating costs.
Our brief was to examine whether C-foils could be safely used in reducing fume cupboard energy consumption and to what degree.

METHODOLOGY

EECO2 conducted an independent study of the C-foil to determine the potential benefits of using the device as an aid in reducing fume cupboard energy consumption.

SOLUTION

Comparison results were based on containment robustness testing using SF6 gas as defined in ISO 14175 also backed up with smoke visualisation tests to show air flow patterns.

C-foils improve the containment robustness of the fume cupboard by reducing the impact of certain external influences such as an operator walking past, thus enabling the safe reduction of the capture face velocity without compromising operator safety.

At 0.4m/s an improvement of between 30 - 50% on containment robustness was seen when the C-foils were installed, enabling the cupboard to provide a similar protection when operating at 0.5m/s (without C-foils).

Significant energy savings in fan, heating and cooling energy were identified due to the subsequent reduction in the required fresh air volume required following the installation of the C-foils. Installation is quick and easy with very little downtime.

Benefits are dependent on fume cupboard design i.e. a fume cupboard that is >15 years is not designed to operate at a face velocity of <0.5m/s and the C-foils may not improve containment sufficiently. Some >20 year old cupboards were tested with C-foils that did not demonstrate any improvement in containment robustness. Benefits vary depending on the supply and extract control system of the fume cupboard and associated laboratory.

RESULTS

Energy savings delivered (per year per fume cupboard)

Energy savings delivered (per year per fume cupboard)

12,900 kWh

Energy cost savings (per year per fume cupboard)

Energy cost savings (per year per fume cupboard)

£371

Emissions reduction (per year per fume cupboard)

Emissions reduction (per year per fume cupboard)

3 tonnes

of CO2

LIKE WHAT YOU SEE?

We can do this for you too. Speak to us today to find out what we can deliver for your business.

BACK TO ALL CASE STUDIES | Get in touch