GMP critical HVAC energy cost reduction in the pharmaceutical & life science industry

1. An introduction to EECO2 - Energy Efficiency Consultancy Limited
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

2. 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 •

3. 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.

4. 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
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)
• 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

5. 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%

6. 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.

7. Current HVAC parameters across the industry
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
 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

8. 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

9. 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

10. 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.

11. Global Energy Reduction – Case Studies
EECO2 has provided multinational support in over 20 countries over the last 8 years

12. 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

13. 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

14. Energy Management Programme – R&D Campus (UK)
reduction
17%
(+2%)
reduction
30%
(+13%)
reduction
32%
(+2%)
reduction
2012
15%
2011
Strategy
Development
with potential for further 20-25%
2010
Data
Validation
2009
aM&T
Implementation
32% Energy reduction over 6 years
2008
Opportunity
survey
2007
Initial
2006
 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.

15. 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

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 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 yrs
or less.

17. Contact Details
For further information, contact:
Keith Beattie
Head of Life Science Division
Energy Efficiency Consultancy Ltd
email: info@eeco2.co.uk tel: +44 1625 660717
www.eeco2.co.uk