How can you improve energy efficiency in a pharmaceutical facility?

Our experience: Develop an Energy Management Action Plan or E-MAP. Adopting the 7 Pillars and engaging Management, Operations and key stakeholders lead to immediate as well as sustained results providing their is engagement in the monthly meetings.

From my experience collect the data on the energy consumption post COVID and build a baseline energy consumption of electrical and gas energy. After the baseline energy consumption data is in place, energy audit of the facility may be carried out. If the pharma facility is in the UK, then there will be an EPC certificate in place, which will give some recommendations on the energy reductions.

Homework before beginning the energy transformation: 1) Assure the C-Suite is (financially/fiscally) passionate about the project. Assure the operations team is passionate about the project. 2) Understand the original design and intent. 3) Obtain18 months of operating and utility data. 4) Gain a complete understanding of which elements in the facility are causing what consumption and load. 5) Develop and implement a robust service & maintenance plan to bring all equipment and systems to 100% of original design intent and capability. 6) Develop YOY utilities post service & maintenance to former 18 months. Now conceive, plan, implement, transform! Saving energy and water by simply replacing everything is guaranteed ... ad quad damnum.

To enhance energy efficiency in a pharmaceutical facility: 1. Upgrade lighting to LED technology. 2. Optimize HVAC systems with energy-efficient models and controls. 3. Implement smart building automation for better energy management. 4. Utilize energy-efficient equipment and machinery. 5. Enhance insulation and seal leaks in the building envelope. 6. Install motion sensors and timers for lighting and equipment. 7. Conduct regular energy audits to identify areas for improvement. 8. Train staff on energy-saving practices. 9. Utilize renewable energy sources like solar panels. 10. Monitor energy usage and track progress to maintain efficiency.

First, engage the staff and users in easy behavioural changes to save energy (conservation). Second, we would need to re-calibrate lighting and HVAC designs based on existing use—past designs may have estimated more users than actual. Once the behaviour and demand are optimised, a system should be designed with leapfrogging technology in mind—start with the best available technology today that will stay relevant longer. The system could be automated with microcontrols focused on locational and time-of-use users. We need to explore the option of connecting the system with solar power, batteries, or electric vehicles parked in the car park by employees; this would flatten the demand curve, reducing the system's overall $/kWh cost.

We have a case examples to replacing existing chiller of SPC 1.1 kW per TR with a new Magnetic centrifugal chiller of SPC 0.58 kW per TR. Another case study of EC fans in place of conventional fans in Air Handling Units, leading to 35% saving in AHU consumption. Over 20-50% of energy cost saving is possible in a 10+ years old chiller system

HVAC equipment is significantly more efficient than it was 10 to 20 years ago. The use of energy recovery and heat pumps is driving the efficiency levels high. Motors are more efficient than in the past and direct drive fans eliminate the loss through the belts and sheaves. An added benefit is the equipment is more environmentally friendly.

In pharmaceutical industries process chillers are used to provide chilled water mixture (glycol +water) at -20 deg C to -48 deg C depends on process requirement. Specific energy consumption for those chillers could go up to 1.5 ikW/TR or more depend on chiller condition. Therefore, it's very important to monitor energy performance of these chillers on regular basis and take appropriate action to maintain their performance. For comfort chiller system automation should be done and it should include both real time monitoring as well as controlling. Chiller plant optimizer should be installed to operate the HVAC system at its best efficiency point with respect to load.

Yes! By using VFD on motors and pumps during implementation will significantly improve energy efficiency. This not only saves energy but also prolongs the lifespan of equipment and reduces maintenance cost as well.

HVAC systems are the largest energy consumers in pharmaceutical facilities, accounting for 30-50% of total energy use Pfizer's Andover, UK, facility Achieved a 20% reduction in energy consumption through HVAC system upgrades, including variable speed drives (VSDs) and improved building insulation. Eli Lilly's Kinsey, NC, facility: Reduced HVAC energy use by 18% through optimizing air handling unit (AHU) controls and implementing free cooling strategies.

Empresas farmacêuticas tem requisitos elevados de qualidade de ilumina??o ao mesmo tempo em que requerem salas controladas, o que dificulta ou impede o uso de ilumina??o natural. Provavelmente uma instala??o como essa já faz uso de tecnologia LED. Um ganho adicional é o uso de luminárias inteligentes que, além do sensoreamento e controle, se comunicam com um sistema central capaz de perceber padr?es e hábitos dos usuários e promover um controle mais eficiente e inteligente ao mesmo tempo em que preserva a qualidade da ilumina??o local.

En mi experiencia, un tema muchas veces no identificado es la sobre iluminación, que constituye un derroche de energía Dado un determinado requisito de iluminación para un determinado ambiente (ya sea regulatorio por razones de salud laboral o requerido por el proceso), proveer iluminación por encima de estos niveles es innecesario y a veces contraproducente, no solamente por el sobre consumo de energía que significa, sino también porque puede provocar deslumbramiento y quizá accidentes, si una persona llega a este ambiente desde otro con menor iluminación

must promote employee education and engagement, it is important to educate the building occupants about the advantages of using smart lighting and practicing energy-saving habits. Encourage them to effectively utilize lighting controls and report any issues or concerns promptly. To foster a culture of energy conservation and sustainability, create awareness among the employees, and encourage their active participation in energy-saving initiatives."

The first thing to be implemented is to change to LED lighting, but ensure that you are installing good quality fittings and that you achieve the required lighting levels - it's not just a matter of swapping fittings. Then use occupancy and vacancy sensing to switch off lighting when not required. The need for dimmers, timers and daylight harvesting can be evaluated based on the building structure and the utilisation of the rooms.

Smart Lighting with LED is a good return on investment, with less heat in the area, savings Air Conditioning costs also. There is also t5 to t3 solutions and de lamping areas also.

In my opinion, two crucial factors for designing an energy-efficient compressed air system are: 1. Compressors with IE4 motor efficiency (iPM) and advanced Permanent magnet drive train technology can save up to 35-40% energy, achieving an SEC as low as 0.14 kW/CFM, greatly reducing overall energy consumption. 2. Aluminum piping offers significant advantages over traditional materials, with studies showing potential 50% installation cost savings due to its lightweight design and push-to-connect fittings. Its corrosion resistance minimizes pressure drops and leaks, ensuring uninterrupted airflow and potential 10% energy savings. Combined with proper pressure separation, aluminum systems enhance air quality and reduce maintenance needs.

In my experience I have noticed that the importance of understanding your compressed air demand profile is often over looked when sizing new air compressors. This can result in operating a compressor outside its sweet pot which results in an unnecessary high specific energy consumption (SEC) over the assets lifetime. A critical operational performance parameter that is commonly forgotten about is the monitoring of the outlet air temperature of the air compressor. This highlights the effectiveness of the cooling and how close the compressor is to the ideal isothermal process. It can be challenging to get data like this from some manufacturers but it should be included as a deliverable on any new air compressor projects.

I have identified with several of my clients that have high compressed air consumption that aging / leaking equipment and piping infrastructure can be a significant contributor to inefficiency and higher energy consumption. Investment in routine maintenance, leak detection and rapid replacement of defective materials is far more cost and energy efficient than simply adding additional capacity.

The compressed air system requires continuous monitoring to ensure optimal operation. Monitoring compressor energy consumption is crucial. In an energy monitoring system, "heat map" graphs display each equipment's energy consumption throughout the day using different colors. Blue or green indicates low consumption, while orange or red tones signify higher consumption. If a compressor shows yellow or orange outside working hours, there may be issues like an air leak or unnecessary equipment operation, resulting in wasted money. Energy monitoring helps identify areas for improvement and optimize resource usage.

It pays also to look for air leaks as this also is a wasted energy and is a easy fix to remedy. a Variable speed drive on extraction fans is also a option.

Here are some key ways to improve energy efficiency in these facilities: Conduct an Energy Audit: This is the first step to identify areas for improvement. Install programmable thermostats and occupancy sensors to adjust temperature and ventilation based on real-time needs. Upgrade Lighting Systems: Replace traditional lighting with energy-efficient LED lights. Implement occupancy sensors and dimming controls to further reduce lighting energy use. Renewable Energy Sources: Explore options for on-site renewable energy generation like solar panels to offset energy consumption from the grid. By implementing these strategies, we can significantly reduce their energy, leading to cost savings and a more sustainable operation.

Continual processes to reduce, recycle and re-use across all activities. Look for opportunities to use process waste streams for potential reduction, re-use, or as a fuel for power generation. Assess opportunities for receiving waste heat from on-site /third-party sources. Assess potential for ground-source or air-source heat pumps. Consider PV deployment across multiples areas, including roofs, car parks, facade, windows, walkways,etc. Assess potential for on-site wind turbine application.

I wouldn't say adopting renewable energy sources improves energy efficiency. What I like is that this is listed as one of the final points, as we should always prioritize energy efficiency first and then explore new energy alternatives. Renewable sources reduce energy consumption from possibly fossil fuel sources, but it doesn't directly translate to an energy efficiency measure (perhaps only because distribution losses decrease when using on-site generated energy). What I highlight as positive is the use of renewable sources, contributing to reducing emissions into the atmosphere.

First reduce energy consumption and improve energy efficiency. This will reduce the required rating of any renewable energy system, especially the required battery size if using a hybrid system.

1/. Audit the entire companies need to produce both heat and cool energy , calculate it as the maximum demand in Kilowatts needed in both areas 2/. next gragh or plot time and temperature needed in every area you have now identified 3/. look at the maximum cooling and heating figures and ensure you understand precisely the time it is needed for 4/. if your maximums are short term loads note that as hrs and minutes at max for heat and cool kilowatt requirements 5/. Then group up the next areas in time over 1 hr and note the kilowatt load values 6/. Decide now do you wish to run a chiller and a heat pump or do you wish to introduce evaporation and condensing thermal batteries Points 7 to 15 can be added but be prepared for a shock !

Without training to the people that will run any energy system you will only need to automate all systems. Training comes at different levels: design, operation and maintenance.

Create a culture in staff to think about cost benefit analysis and ROI, KPIs wise Committee and Rewards Recognition scheme, such initiatives can help overall efficiency improvements approach in an organisation.

By Using the lean six sigma practices, it makes it easier to identify the small fruit with improvements. Communication is the key in all areas of management.

Conduct assessments to match cooling and heating sources and sinks to optimize the energy balance in these energy intensive environments

There are lots of activities that can lead to higher energy efficiency in pharmaceutical industry. Documenting the energy consumption baseline in a database and having different data analysis of diverse groups of businesses can put light on less understood areas of energy optimization. Engaging, motivating, training and assisting all layers of business to suggest improvement areas in better energy management and cascading support to research and development of the suggested ideas can lead to a big difference. Retrofitting the workstations, machinery and vehicles together with using renewables energies and considering multilateral requirements of GXP and energy management can boost the innovations in optimizing energy consumption.

Make sure you have a BMS in place, running and well maintained. BMS should be integrated to all equipment in the building for control, monitoring and scheduling of building activities and equipment. On the Top of the BMS you can connect to an Artificial intelligent software as Brainbox AI to optimize the usage of HVAC equipment since HVAC contribute to 50-60% of the energy consumption in buildings. with Both well running and maintained BMS and AI, you can achieve large significant amount of energy saving around 35% without any CAPEX. Other additional methods can be implemented as renewable energy, energy Audit and others to name few which helps contribute to energy saving however capital is needed.

I recommend the following based on my experience in PMC/EPC of critical built environment 1. Create dashboard for energy on real time basis by collecting data from BMS. This will enable to optimise energy consumption and efficiency by smart load scheduling and load shedding. 2. Log the energy data in a Historian. This will help to identify undue energy leaks and abnormal spikes in energy 3. Adopt the above approach for water. Treated water consumes energy. Any leakage in water or abnormal rise in the flow can alert the operation manager to fix the causes. 4. Install leak detection system for water and hydrocarbon piping. 5. Install IOT sensors at strategic locations to collect energy and water flow data . Use AI and ML for patterns.

Consider if any of the operation can be separately metered and operate during off-peak hours and take advantage of time-of-use rates.