This document outlines strategies for reducing energy use in pharmaceutical HVAC systems. It identifies common areas with high energy savings potential, such as reducing air change rates and implementing night/weekend setbacks. Barriers to energy reduction like lack of funding and QA approval are discussed. The presentation recommends hosting team-based "energy kaizens" to identify opportunities and gain stakeholder buy-in. Case studies show projects at pharmaceutical plants that cut HVAC energy use up to 66% by optimizing air flow and implementing variable speed controls.

1. A practical approach to pharmaceutical HVAC energy reduction
29 Oct 2013
Spirax-Sarco, Cheltenham
Keith Beattie
Head of Life Science Division
Energy Efficiency Consultancy Ltd

2. Agenda
1.
Introduction to EECO2
2.
HVAC Energy Hogs – The ‘Usual Suspects’
3.
Barriers to energy reduction
4.
Proven techniques to overcome barriers
5.
Case Studies
6.
Summary & Discussion

3. Who are EECO2
Combined 100+ years experience of Design, Build & Operation
of Hi-tech, Life Sciences & Industrial Facilities
8 years providing global energy efficiency project
implementation and support
Sharing industry best practice solutions
Empowering & supporting sites to deliver locally
Capital avoidance approach
Safely driving innovation within industries where product quality
is critical
70+ energy workshops delivered & supported globally
Clients we have worked with include: Pfizer, GSK, Eli Lilly, Novartis,
Sanofi, DSM, Ipsen, Camfil, NHS,
• benchmarking & modelling • capital project sustainability design reviews • energy engineering standards • energy project development & site
support • project management & turnkey delivery • pre & post project energy monitoring • laboratory energy reduction •

4. The Usual Suspects
Facility Type
Opportunity
Potential Reduction
All
Lower air change rates; fresh air reduction
30-45%
Laboratories
Reduce fume cupboard capture face velocity; introduce system diversity; convert CAV to
VAV
20-30%
All
Night/Weekend Setback
15-25%
Offices/non-GMP areas
Night/Weekend shutdown of non-GMP areas
12-18%
All
Chilled water temperature management and control upgrade
13-15%
All
Remove redundant plant no longer required due to product changes – redundant safe
change units, multi HEPA filtration layers, dehumidifiers, heating & cooling, etc
10-15%
Manufacturing/Packaging
Reduction of manufacturing spatial requirements i.e. enclose temperature/humidity
vulnerable product to reduce conditioned space volumes
10-15%
All
Improvement in BMS control strategy & set points control
8-12%
Manufacturing/Packaging
Improvement in dehumidifier heat recuperation
7-12%
All
Installation of high efficiency filtration – AHU, safe change & HEPA
5-7%
Warehouses
Air destratification; ventilation improvements; control linked to temperature mapping;
eliminate fresh air
5-7%

5. Air Change Rate / Set-Back
Flow Rate is directly proportional to
rotational speed of fan motor.
If Flow Rate is halved, then Power is
reduced by factor of 8;
and Pressure is reduced by factor of 4.

6. Current HVAC Values vs. Trial Results
Company
Grade A
Grade B
Grade C
Grade D
CNC (OSD)
A
0.5 m/s
30 acph
20 acph
15 acph
12-20 acph
B
0.5 m/s
45 acph
25 acph
15 acph
15 acph
C
0.5 m/s
60 acph
40 acph
25 acph
15-20 acph
D
0.5 m/s
More than 20
acph
More than 20
acph
More than 10
acph
More than 10
acph
E
0.45 m/s
40 acph min
20 acph min
20 acph min
F
0.45 m/s
40 acph
25 acph
15 acph
15-20 acph
Trial Work
Operational
0.25 to 0.35 m/s
10 acph
5 acph
5 acph
Less than 5
acph
Trial Work at
Rest
0.15 m/s
10 acph
5 acph
~ 0 acph
~0 acph

7. What barriers exist to reducing energy / cost?
No finance / budget available
Lack of confidence in savings/cost predictions – can not prove benefits
QA won’t agree to change
Difficulties in finding the right expertise
No resources available
Can’t get the downtime / plant availability
Too busy dealing with other issues – its not a priority

8. Energy Kaizens / Interventions
Team based, focussed energy/water savings event
Involves/engages all stakeholders
EECO2 facilitate site teams to identify opportunities and to devise
solutions – engagement & buy-in
Follows DMAIC process
• standard Operational Excellence tools
• but focussed on sustainability & cost
Typical output:
• JDI’s;
• scoped & costed projects;
• projects for further investigation
EECO2 have delivered over 70 events for several global clients.

9. Energy Kaizens / Interventions
Findings/Observations:
1. HVAC opportunities identified across all sites: air change reduction; fresh air reduction; BMS optimisation; out-of-hours setback;
maintenance opportunities
2. Energy management practices are in their infancy on most sites – with undeveloped metering/analysis, KPI’s, use of energy
teams, continuous commissioning & site communications
3. Site teams engage well with the intervention process
4. QA / EHS buy in to projects is critical & process works to deliver this
5. External consultant facilitated, but site team responsible for decisions
Results:
Saving Identified
(MWh per yr)
% of Site
energy / cost
No of
Projects
No of
Investigations/
JDI’s
Cost Saving
per year
Project Cost
Estimate
Simple
Payback (ROI)
A
3,606
17% / 20%
n/a
n/a
€221K
n/a
n/a
B
7,698
12% / 20%
11
107
€620K
€1,085K
1.8yrs
C
6,310
11% / 15%
4
78
€573K
€1,305K
2.3yrs
D
5,146
6% / 13%
5
220
€319K
€670K
2.1yrs
Site
Investment capital cost per MWh saving: €110-206 per MWh reduction

10. Case Studies
Global Pharma Company – R&D Campus Building

11. Global Pharma Company – Mixed Use Building
Building contains mixture of operations including

Laboratories

Test Facilities

Solid Dose manufacturing

Sterile manufacturing
The use of this building has changed considerably in recent years and a through design & optimisation review
will yield considerable savings.
EECO2 carried out a high level data collection audit to enable a Concept review of energy saving opportunities
within the building. The concepts proposed included:
•
Reducing fresh air intake by re-configuring the HVAC system
•
Introduction of a variable air volume system for laboratory fume cupboards & reducing air change rates
•
Introduction of low energy filters and high efficiency motors
•
BMS optimisation review
We have identified opportunities within the Sterile Manufacturing area, but would not recommend making any
changes at this time, one step at a time

12. Global Pharma Company – “Size of the Prize”
Building 510
Description
kWh
Air change reduction
HVAC Set Back
Fresh Air reduction
BMS Optimization
HEM Motors & VSD's
High Efficiency Filtration
Totals
% of HVAC Totals
1,542,011
1,064,285
3,269,197
1,030,960
126,889
149,150
7,182,492
42%
£
T. CO2
124,889
46,256
128,784
83,499
10,277
12,080
405,785
40%
1,420
134
131
950
117
137
2,889
46%
Based upon 2011 data & January 2013 Energy costs, savings
have been success factored
HEM Motors & High Efficiency
VSD's
Filtration
2%
2%
BMS
Optimization
14%
Air change
reduction
21%
HVAC Set Back
15%
Fresh Air
reduction
46%

13. Case Studies
The Wilton Centre

14. The Wilton Centre (ex ICI laboratories)
Existing System
•
•
•
•
T Block Older style Face & Bypass cupboards. Over 100
Individual extract fans serving upto 3 Cupboards (50No)
Header system with 2 large run & standby fans
4 Large 100% FA systems
Delivered
•
•
•
•
•
•
•
•
•
50 % diversity Engineered into the systems
Remove individual extract fans
Retrofit VAV valves & controls to every FC within ceilings
Carried out while labs in use with 1 weeks downtime per lab
FC controller fitted to every cupboard
Pressure control to every lab
Supply VSD & static pressure control fitted
Extract header Bleed damper & static pressure control
Weekend Commissioning to reduce disruption.

15. Nov-11
Sep-11
Jul-11
180
May-11
200
Mar-11
Jan-11
Nov-10
Sep-10
Jul-10
May-10
Mar-10
Jan-10
Nov-09
Sep-09
Jul-09
May-09
Mar-09
140
Jan-09
Nov-08
Sep-08
Jul-08
May-08
Pre Project Metered Energy Use
Mar-08
Jan-08
Nov-07
Sep-07
Jul-07
May-07
Mar-07
Jan-07
Nov-06
Sep-06
Jul-06
May-06
Mar-06
Jan-06
Nov-05
Sep-05
Jul-05
May-05
Mar-05
Jan-05
Case Study - Wilton Centre (Ex ICI laboratories - T-Block)
Metered data from Lab Block based on ~100 Fume Cupboards
T-Block MW.h
66% Energy
Reduction
160
Post Project Metered Energy Use
120
100
80
T-Block MW.h
60
40
20
0

16. Summary
 HVAC is one of the most significant energy users in pharmaceutical & bio-pharmaceutical
manufacturing.
 A risk based approach founded on sound data can be used to challenge established company
norms. Large savings can be achieved at getting back to company standards.
 Technically, the reduction solutions exist and are well proven. Barriers to improvement are often
related more to people engagement – soft skills are important.
 The collaborative approach of the HVAC intervention engages all stakeholders and facilitates the
site teams identifying the right solutions for their sites.
 Simple payback of HVAC energy reduction projects is almost always under 3 yrs and often 2 yrs
or less.

17. Questions?
For further information, contact:
Keith Beattie
Head of Life Science Division
Energy Efficiency Consultancy Ltd
email: keith.beattie@eeco2.co.uk mob: 07825 371 432