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Client: Global Pharmaceutical Manufacturer

Location:

Site:

Date:

Sector:

South Africa

Consumer Health

December 2011

Pharmaceutical/Life Sciences

Energy Efficiency Case Study

Tablet Manufacturing Suite HVAC Upgrade I Global Pharmaceutical Manufacturer, Cape Town The project: The cost of electrical energy in South Africa has risen very significantly over the past 4 years and is projected to continue rising for the immediate future. EECO2 was called upon by a global pharmaceutical manufacturer to their Tablet Manufacturing Suite facility in Cape Town, South Africa to assist them reduce energy demand without compromising on product quality or regulatory compliance.

0.5

2010

2011

2012

0.7

1.05

1.5

Cape Town’s energy cost increase projections in SAR/kWhr

EEC02 Energy Efficiency Services Pharmaceutical Energy Services

Benefits Delivered: • Energy savings delivered • Energy cost savings • Emissions reduction • Simple pay back

3

Energy Monitoring Services 363,000 kWhr/pa SAR: Equivalent to £36,000 /pa 336 te CO2 18 months

Project Management Energy Consultancy

3 3

EPBD Compliance Sustainability & Renewable Solutions

www.eeco2.co.uk


The EECO2 solution:

“It’s 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.

• 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 elimination:

The unique challenges: The Tablet Manufacturing Suite presented some unique challenges for the team. The global pharmaceutical manufacturer’s products and manufacturing techniques have developed rapidly over the years but the HVAC system in this facility in Cape Town, South Africa was largely the same as originally designed some 15 years ago. • 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 none operational setbacks • All without impacting on product quality or manufacturing output In addition to supplying conditioned air to the manufacturing area, the HVAC system also had to dehumidify large volumes of fresh air to provide for personnel, pressure cascades and dust extraction requirements.

• From the project’s inception risk elimination was the team’s core focus • 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 adverse approach. Off site support: EECO2 supported HVAC design, product risk assessment, on site commissioning Luwa provided the local engineering & technical support to deliver the implementation .

For further information: GENERAL ENQUIRIES & SALES Tel: +44 (0) 1625 660 717 Email: info@eeco2.co.uk TECHNICAL SUPPORT Tel: +44 (0) 1625 660 717 Email: info@eeco2.co.uk EEC02 Limited Suite 9, The Green, Fountain Street, Macclesfield, Cheshire, SK10 1JN info@eeco2.co.uk www.eeco2.co.uk


Energy Efficiency Case Study - Tablet Manufacturing Suite HVAC Upgrade