Pharmaceutical Case Study

One of the largest medical device manufacturers in the United States. Multiple facilities. Founded in 1989. Market cap over $693 million.

Business Situation

Integra’s production facility runs 2 ½ shifts 5 days a week. The manufacturing equipment loads include compressors, pumps, presses, drills, sanders, lathes, etc. The manufacturing process also involves the use of three large Hull Lyo refrigeration systems. The lighting system is comprised primarily of T-8 32 Watt fixtures. The HVAC system consists of 23 roof top split systems. The facility’s energy costs were high and trending steeply higher and needed to be controlled.

Process

As a first step Energy Edge Technologies Corporation (EETC) conducted a comprehensive whole building investment-grade energy audit and engineering study of Integra’s facilities. The audit included an intense review of the following areas:

Utility Bills: EETC reviewed the previous 12 months of utility data for the facility.

Designs: EETC reviewed all available electrical one line and mechanical drawings.

Facility Energy Behavior: EETC reviewed with the customer the current energy behavior of the staff including temperature set points, setting back temperatures when the facility is closed, turning off lights, office equipment, etc. after hours.

Building Envelope: EETC checked weather stripping, insulation, open doors and areas around frequently trafficked areas, etc.

Lighting Systems: EETC reviewed the current lighting systems to determine if the most efficient lighting options were being used and if occupancy sensors, timers and dimmers had been placed into operation. EETC also looked for areas that were over lit and areas that could take advantage of natural sunlight.

Heating, Ventilation and Cooling Systems: EETC looked at the HVAC/R systems to determine operating efficiency, maintenance schedules, filter replacement frequency, age, and upgrade and treatment options.

Motors and Equipment: EETC itemized all electrical loads across the facility (including HVAC, production and refrigeration equipment) and their respective run times. Actual electrical measurements such as amperage, voltage, THD%, power factor, etc were taken at all loads as well as at the main. Load, duty cycles, operating efficiency, age, replacement and treatment options, etc. were all determined.

Solution

Energy Edge Technologies Corporation (EETC) recommended a whole facility approach to energy cost reduction including all available energy conservation opportunities to significantly reduce the facility’s expenses. EETC also showed the customer how each different option would impact energy consumption as well as project cost and return on investment. Based on EETC’s analysis and Integra’s selection of available options, Integra was guaranteed a minimum kWh reduction of 12.88% and a maximum project payback of 24 months. EETC offered Integra different financing options and assistance but the customer chose to use available capital. EETC takes complete responsibility for all turnkey installations including the procurement of all equipment, labor, project management, pre- and post- inspections, waste removal, recycling, certifications, permits, administrative rebate work, etc.

Benefits

EETC measures the success of all projects in accord with the International Performance Measurement and Verification Protocol, Option C (www.IPMVP.org) as approved by the U.S. Department of Energy. EETC compiles a statistical measurement and verification report quarterly for customers which includes utility bill analysis, base and verification period comparison, building simulation/ modeling, inclusion of all factors of influence, statistical correlation, regression analysis, etc. After completion of the turnkey project and continuing measurement and verification, Integra has been enjoying an average annual kWh reduction at this plant of 16.62%. The turnkey project paid back in less than 17 months which provided Integra with a 71% return on investment.

Products and Services Recommended and/or Employed

• Lighting upgrade to new 25 Watt, T-8 lamps with high efficiency ballasts
• De-lamping from four lamps to two lamps with Miro 4 polished aluminum reflectors
• Variable speed / frequency drives to match process demand and machine output
• Anti-compressor short cycling for air conditioning and heating systems
• Electrical sine wave modification at branch lighting circuits
• Anti-compressor short cycling for refrigeration loads
• Oil supplementation for hermetically sealed lubrication systems
• Occupancy sensors across office spaces and manufacturing areas
• Recommended changes in staff energy behavior
• Energy management based on occupancy