Energy Saving Strategies in Pharmaceutical Manufacturing Plants

Energy usage is one of the biggest business costs in pharmaceutical manufacturing facilities. Modern pharmaceutical factories have complex facilities that include HVAC systems, purified water, compressed air, cleanrooms, production equipment, cooling and an automated manufacturing line, all of which require large quantities of electricity, gas and fuel.

I have often seen pharmaceutical companies look to improve production efficiencies and compliance but don’t fully understand how much utility mismanagement costs them. In many of my audits of pharmaceutical manufacturing facilities, I have found that through HVAC imbalances, leaking air compressors, oversize motors, leaking steam traps and poor operation procedures, there are significant amounts of wasted energy with no one knowing about them.

Unlike many industries, pharmaceutical manufacturers cannot operate with reduced energy consumption if they negatively impact environmental controls or product quality. All energy saving initiatives must comply with GMP's, cleanroom standards and validated operating conditions.

A well-defined energy optimization program improves both your bottom line, as well as enhances equipment reliability, sustainability and long-term manufacturing efficiencies.

Why Energy Consumption is High in Pharmaceutical Plants

Facilities that manufacture pharmaceuticals must have a regulated manufacturing atmosphere that is operational 24 hours a day, 365 days a year. The largest consumers of energy in the production process include:

• HVAC systems
• Water creation systems
• Steam production systems
• Compressed air systems
• Cleanroom pressure measurement systems
• Coolers
• Process equipment
• Lighting

Manufacturers that produce sterile products generally use an even greater quantity of energy in their facility because they have a higher standard for temperature, humidity and air quality (cleanliness).

In many plants, the HVAC system alone accounts for greater than 50% of the total energy consumed by the facility.

Optimization of HVAC System: The Largest Opportunity!

HVAC systems account for a large amount of energy used in pharmaceutical manufacturing facilities.
They provide:

• Maintaining temperature
• Maintaining humidity
• Filtration of air
• Maintaining pressure differentials
• Classifying cleanrooms

The very nature of HVAC systems running all the time means that even small inefficiencies can produce significant utility expenses as time goes on.

1. Common HVAC Energy Losses

During a facility audit there are many items I routinely find, for example,

• Dirty HEPA filters
• Unbalanced air
• Too many air changes per hour
• Simultaneous heating and cooling
• Poorly insulated piping
• Duct leakage

These problems add to the load on the fans and increase the demand for cooling, therefore increasing the cost of operating.

2. Effective HVAC Energy Saving Measures

Energy optimization methods include:

• VFDs on air handling units (fans)
• Demand based air change control
• Pressure cascade optimization (high to low)
• Preventative filter maintenance
• Chilled water optimization
• Insulating ductwork and pipe

However, any HVAC system changes must first be evaluated scientifically to ensure that the GMP compliance and environmental qualification are still valid.

Optimization of Compressed Air Systems

The cost of compressed air is another significant expense for pharmaceutical companies. Compressed air systems are generally the most inefficient utility systems when they are poorly managed.

Many facilities I have seen have compressed air leak rates that exceed 20%, which creates ongoing waste of energy.

1. Common Problems in Compressed Air Systems

Typical Problems with Compressed Air Systems Include:

• Leakage of air from joints or valves
• Incorrect pressure settings
• Sequencing of compressors that is not optimal
• Presence of moisture
• Poorly implemented preventative maintenance

These issues require larger amounts of electricity to keep the compressors operating longer.

2. Energy Saving Opportunities

Energy efficiency opportunities include:

• Routine leak detection
• Pressure optimization
• Installation of energy efficient compressors
• Automatic compressor control
• Properly sized piping
• Preventative dryer maintenance

Minor reductions in air leakage from a facility's compressed air systems can lead to very large annual savings.

Steam-System Efficiency Improvements

Steam is used in very many activities in the pharmaceutical industry that require the use of steam for:

• Sterilization
• Heating processes
• HVAC humidification
• Operational activities

There are significant losses of energy in "steam systems" if steam systems are not managed properly.

Common Steam Energy Losses

The most common losses of energy associated with steam include:

• Steam leakage
• Failure of steam traps
• Losses of condensate
• Insufficient insulation of pipes, vessels, etc.
• Oversized boilers

Not only are these types of steam losses wasting energy, but they also are reducing the reliability of the entire steam system.

Strategies for Steam Optimization

To improve energy use in a steam system, several energy-conservation methods can be applied, including:

• Establishing a steam trap monitoring program
• Installing a condensate return system
• Measuring the efficiency of the steam boiler
• Improving insulation on pipes, vessels, etc.
• Properly loading the steam boiler

It is important to conduct steam audits on a regular basis to identify any unidentified steam losses.

Purified Water System Energy Management

Water for Injection (WFI) and purified water systems are vital utilities in pharmaceutical manufacturing but also contribute significantly to energy consumption. Major areas of electricity usage include:
- Pumps
- Heaters
- Distribution loops or networks
- Reverse osmosis systems
- Distillation units
Additionally, the continuous recirculation and sanitization of these systems can significantly increase total utility usage.

Areas of Optimization

Some areas for improvement include:
- Pump optimization
- Heat recovery
- Loop temperature optimization
- Efficient sanitization scheduling
- Preventive membrane maintenance
Any optimization of water systems must not compromise microbial control or validated operating conditions.

Lighting System Optimization

Lighting isn’t typically the biggest electricity user in a pharmaceutical facility. It does make up a large portion of your overall electricity usage. Older buildings tend to keep using old inefficient lighting systems much to their detriment.

Effective Lighting Improvements

• Convert to LED Lighting
• Install Occupancy Sensors
• Use Zone Controls for Lighting
• Regularly Clean Light Fixtures

Energy efficient lighting will lower HVAC load as well because of the reduced heat produced from the lighting source.

Equipment Right-Sizing

One frequently overlooked reason for wasting energy is using equipment that is too large for the application. Many pharmaceutical facilities use:

• Chillers that are too large
• Pumps that are too large
• Compressors with excess capacity
• HVAC systems that are overengineered

Often oversized systems operate inefficiently because they are often run at less than full load.

In my experience, right-sized study of equipment sizing will disclose much higher opportunities to reduce utility costs than most people realize.

Variable Frequency Drives (VFDs)

Variable frequency drives (VFDs) offer excellent energy savings on rotating equipment. Common applications include;

• AHU fans
• Cooling tower motors
• Pumps
• Compressors

Rather than operating at full speed all the time like conventional motors do, variable frequency drives (VFDs) can adjust the motor's speed to match the process demand.

Preventive Maintenance and Energy Efficiency

Equipment that is not properly maintained can be less energy-efficient than well-maintained equipment.
Examples of this include:

• Highest load on fans = dirty filters
• Lowest efficiency = fouled heat exchangers
• Best resistance on motors = worn bearings
• Excess power consumption = misaligned pumps

A good preventive maintenance system can help improve equipment conditions and energy efficiency.

Energy Optimization in Cleanrooms

The regulation of the environment in a cleanroom setting is a major obstacle to the reduction of energy; nevertheless, there are opportunities to achieve significant energy savings through a variety of methods.

Areas for Improvement
Optimized air change rates
Airflow control based on occupancy
Optimal pressure differential
Effective practices for cleanroom clothing
Many cleanrooms in facilities continue to operate at peak airflow rates and thereby consume oodles of energy even when they are not actively producing items.

Automation and Energy Monitoring

The trend to automate energy management and thus the use of energy management systems (EMSs) within the pharmaceutical industry, continues to grow. An EMS provides pharmaceutical manufacturers real-time insight into their use of:

• Electricity
• Steam
• Water
• Compressed Air
• HVAC systems

Through the use of trend analysis, abnormal utility usage (such as electricity, water, etc.), can be detected early on. If not properly monitored, the majority of energy waste will go undetected for multiple years.

Heat Recovery Systems

Using heat recoveries is an effective way to save energy in the long term. Among many uses, the recovered heat can be used for:

• Heating boiler feedwater
• Reheating HVAC air distribution systems
• Heating process water

In pharmaceutical production facilities generating large quantities of waste heat will result in significant fuel savings as a result of using heat recoveries.

Employee Awareness and Operational Practices

Operator awareness is essential for achieving energy efficiency through the use of technology. Uncontrolled waste of energy is common in many facilities caused by :

• Leaving machinery running
• Doors open in controlled areas
• Improper shut-down of equipment
• Excessive usage of compressed air

Training programs to educate on how to conserve utilities should not interfere with GMP (Good Manufacturing Practice) operations.

Energy Audits in Pharmaceutical Plants

Regular and periodic Energy Audits can allow for the orderly identification of systematic inefficiencies that exist within a facility's operations. An extensive energy audit would review the following:

• Utility consumption pattern
• Performance of equipment and machinery
• Load balancing of systems
• Losses from systems/equipment/machines
• Opportunities to optimize system operation.

Facilities with regular energy audits typically will have higher levels of operational efficiency long-term compared to those without energy audits.

Sustainability and Regulatory Expectations

The development of a sustainable, environmentally responsible, energy-efficient global pharmaceutical company is a growing trend for major global pharmaceutical manufacturers. The operation of energy-efficient facilities is supportive of:

• Carbon reduction goal achievement
• Supporting the implementation of ESG initiatives
• The reliable operation of GMA processes
• Cost competitiveness to drug manufacturer for drug product manufacturing

Regulatory agencies do not have an immediate interest in how utilities are managed; however, inefficient utility management can adversely impact the reliability of the manufacturing process and the implementation of environmental controls.

Achieving GMP Compliance while Saving Energy

An important thing to consider in Pharmaceutical Energy Management is maintaining validated conditions. I have witnessed facilities' efforts at aggressively reducing utility usage;

• creating temperature fluctuations
• creating humidity instability
• causing pressure imbalance
• creating cleanroom classification failures

To achieve energy savings your initiatives must undergo appropriate risk assessments, qualification reviews and change control evaluations prior to being implemented.

Best Practices for Energy Management in Pharma

Proficient, energy management systems exist for pharmaceutical manufacturers; therefore there is a recommended set of proactive steps that can be taken in the form of best practices.

Best Practices Recommended
- Routine energy audits
- Continuous monitoring of utility patterns
- Proper maintenance of HVAC
- Implementation of compressed air leak programs
- Scientific optimization of airflow in cleanroom
- Automation, for utility monitoring
- Utility performance review at periodic, management review meetings
Energy management should be regarded as an ongoing operational strategy as opposed to a one-time project.

Pharmaceutical plants must perform in a way that maintains a balance between operational efficiency, compliance with GMP regulations, the environmental control and the assurance of product quality through the use of their HVAC systems (Heating Ventilation Air Conditioning), compressed air networks, steam generation and water systems. Each of these is one of the largest prospects available for reducing operationally related costs when managed properly.

In my experience, the most successful pharmaceutical facilities manage energy usage from a systematic approach using a combination of preventive maintenance, automation, data monitoring, engineering optimization and process improvements through continuous improvement programs. Rather than just focusing on utility reduction, they focus on incorporating energy efficiency into their overall Operational Excellence and Sustainability initiatives. As the pharmaceutical industry becomes more competitive, Energy Efficient Manufacturing has become a critical aspect of long-term business success and reliable operations.

Regulatory References

1. WHO Good Manufacturing Practices Guidelines
2. US FDA 21 CFR Part 211 Current Good Manufacturing Practice
3. EU GMP Guidelines Volume 4
4. ISO 50001 Energy Management Systems
5. ISPE Baseline Guide: HVAC and Sustainability Concepts

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