GMP critical HVAC energy cost reduction in the

pharmaceutical & life science industry

Keith Beattie CEng MIET Chartered Energy Manager MEI

EECO2 - Head of Life Science Division

2014

An introduction to EECO2 - Energy Efficiency Consultancy Limited

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 – making best use of existing assets

Safely driving innovation within industries where product quality is critical

70+ energy workshops delivered & supported globally

Clients we have worked with include: AstraZeneca, Camfil, DSM, Eli Lilly, GSK, Ipsen, MedImmune, NHS, Novartis, Pfizer, Sanofi,

• 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 •

What do EECO2 offer?

1. Single source of Global HVAC energy saving solutions.

2. Ability to benefit from 12 years of experience, delivering Energy savings to critical HVAC Systems.

3. Process from initial opportunity identification:

• Initial review of HVAC systems to identify potential opportunities = determine viability;

• Develop concept designs, scope & impact assessments;

• High level review of opportunities with key stakeholders e.g. QA, Production, EHS, Lab Owners, Maintenance Engineering etc;

• Risk based approach to define scope & potential savings;

• Develop projects to CapEx with costs/benefits/payback etc;

• Safety/compliance risk assessments and mitigation plan;

• Detailed design, support implementation, commissioning;

• Support development & completion of Regulatory documentation;

• Verify savings delivered;

• On going energy monitoring (continuous commissioning) support to sustain improvements.

EECO2 Support Global Pharma Clients In Best Practice HVAC Energy Reduction

Step 1: Product

Quality Needs

• Temperature

• Humidity

• Area Classification

• Pressure Regimes

Step 2: People

Comfort/Safety

Needs

• Temperature

• Humidity

• Containment

Step 3: Deliver

Business Needs

with minimum

energy

• Model site performance

• Identify potential savings

• Quantify & Scope Deliverable Savings

• Agree ECC / Validation approach

• Deliver savings

• Monitor performance to prove savings

Our unique selling point:

Deep technical expertise in pharmaceutical HVAC regulated

environments combined with a thorough understanding of

QA and regulatory documentation requirements

(Risk Based Approach)

The Usual Suspects – typically, opportunities are found in….

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%

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.

Air change rate reduction & set-back out of hours

is a powerful way to reduce energy consumption,

BUT it must only be implemented with a good

understanding of area cleanliness /

classification supported by robust data.

EECO2 can support sites to achieve substantial

reductions in ACPH and maintain product quality

requirements.

Current HVAC parameters across the industry

Large variation in parameters between different companies and even between different sites of the same company.

These parameters are often based of historical norms, with limited/no data to back it up

EECO2 cleanroom trials demonstrate room classifications can be achieved at much reduced air change rate with no detrimental effect on quality

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

Common barriers to reducing energy / cost?

Lack of available site resource and expertise

QA issues - won’t agree to change

Lack of confidence in savings/cost predictions – can not prove benefits

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

EECO2 provide a unique approach to solving most of the issues above = HVAC Energy Intervention Rapid Improvement Workshop

The HVAC Energy Intervention Rapid Improvement Workshop (RIW)

The HVAC Energy Intervention Rapid

Improvement Workshop IS:

The HVAC Energy Intervention Rapid

Improvement Workshop IS NOT:

Highly collaborative:

• Close team working with site Engineering

• Involving all stakeholders – QA, Production, EHS,

SLT

• A Compliance Audit!

Challenging to existing practices:

• Air change rates

• Pressure regimes

• Temperature and Humidity

• Set back strategies

• Filter strategy – selection and maintenance

• Attempting to identify every possible

opportunity

Focussed on real product quality needs Going to deliver a 100+ page report that is never

read

Differences between Standard Energy Audit & HVAC Energy Intervention RIW Approach

Standard Energy Audit HVAC Intervention/Rapid Improvement Workshop

Experts evaluate site based on their prior experience

& sector knowledge

vs Team based approach engages internal & external

experts to determine what actions are right for the site

Identified opportunities are determined by consultant

experience and sector knowledge

vs Generates large amount of low/no cost actions &

opportunity investigations

Identifies opportunities at time of audit vs Draws in local site knowledge to take account of

historical problems

Consultant retains knowledge vs Learning opportunity for site teams

Report based vs Action focussed

Site sponsor has to “sell” findings & next steps to

other stakeholders

vs Buy in to findings & next steps is inherent to

intervention process – stakeholders are involved in

decisions

Audit findings often have to be integrated into

existing site plans

vs Output is one site plan that captures all opportunities

We are focussed on getting to action and demonstrating real results for clients in a safe, quality compliant way.

Global Energy Reduction – Case StudiesEECO2 has provided multinational support in over 20 countries over the last 8 years

Case Study - Pharma Tablet Manufacturing Suite (South Africa)

Unique Challenges:

• High volumes of fresh air requiring dehumidification in very challenging ambient conditions

• Adapting HVAC system to meet current manufacturing requirements

• Reducing dust extraction system volume – installing VSD

• Initiating non-operational setbacks

• No impact on product quality or manufacturing output

EECO2 Solution:

• Install fresh air pre-treatment to eliminate dehumidification in AHU

• Rebalance area dust extraction system

• Install VSD to maintain dust extraction carrier velocity

• Reduce fresh air volume & rebalance air change rates to reflect area change of use

• Initiate non-operational air volume reduction

• Optimise Building Management System (BMS)

• Provide all necessary documentation, support validation and change control

Client Testimonial:

“Its going to be a tough year for all this 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

Projected Energy Cost

Increase

Pharma Effervescent Product Manufacturing Plant (Argentina)

Project Challenge:

• Very high energy demand driven by the original HVAC design

• Unable to meet product critical relative humidity conditions during summer

Objective:• Reduce site energy demand without compromising product quality

EECO2 Actions:

• Reduce air change rates and fresh air volumes

• Install VSD to supply fans

• Improve air distribution with new diffusers

• Upgrade of filtration and maintenance replacement of control valves

• Re-commission & balance the complete manufacturing HVAC systems

• Completed product risk assessments, Engineering Change Control documentation and all required Regulatory documents.

Client Result:

◦ Energy saving delivered: 1,500 MWh per year (£58,000 GBP equivalent)

◦ Simple payback: 11 months

Client Testimonial:“The savings delivered during phase 1 has exceeded our expectations and the quality team have supported the risk based

approach used to delivery 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 2011.” Site Director

20082007

2009

2006

2010

Initial

Opportunity

survey

2011

aM&T

Implement-

ation

2012

Data

Validation

Strategy

Development15%

reduction 17%

(+2%)

reduction

30%

(+13%)

reduction

32%

(+2%)

reduction

Energy Management Programme – R&D Campus (UK)

Implementation of energy management strategy aligned to ISO50001 EMS;

Supported with data analysis and scoped/developed energy & water reduction projects;

Performed Lab fume cupboard trials to demonstrate containment at lower face capture velocities.

32% Energy reduction over 6 years

with potential for further 20-25%

Case Study - Wilton Centre Business & Science Park (UK-Laboratory)

Existing System:

• T Block Older style Face & Bypass cupboards. Over 100

• Individual booster fans serving upto 3 Cupboards (50No)

• Header system with 2 large run & standby fans

• 4 Large 100% FA systems

EECO2 Actions:

• 50 % diversity Engineered into the systems

• Remove individual booster 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.

Client Result:

• Over 50% reduction in HVAC energy consumption, saving £205,000 GBP per year

• Typical simple payback under 2 years

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 energy intervention rapid improvement workshop 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 yrsor less.

For further information, contact:

Keith BeattieHead of Life Science Division

Energy Efficiency Consultancy Ltd

email: info@eeco2.co.uk tel: +44 1625 660717

www.eeco2.co.uk

Contact Details