BFS filling room air change rate reduction - Case Study

Aim to reduce air change rates, thereby cutting energy demand

Sector: Pharmaceutical

Client: Sterile pharmaceutical manufacturer

Location: Australia

Project Challenge

HVAC designed to provide Grade A room conditions at high energy cost is now only required to provide Grade C room conditions for a BFS filling line.

Project Brief

Phase 1 brief was a trial for four out of eight rooms to reduce air change rate and therefore energy demand while maintaining the required airflow patterns for product protection. Phase 2 brief was to deliver air change rate reductions on all 8 rooms based on Phase 1 lessons learnt.

Solution

  • Carry out as found testing for airflow measurements, room balance, ‘as found’ airflow visualisation to ISO 14644 methodology.
  • Reduce existing air change rates and re-commission and balance each filling room.
  • Validate new air change rates and airflow distribution using airflow visualisation to ISO 14644 methodology.
  • Validate new cleanroom classification to ISO 14644 methodology.
  • Remediation work identified and carried out on an additional AHU which resulted in energy savings and potential future breakdown avoidance.
  • Completed to Planned Change Control, FRS, IOQ documentation.
  • Reduced annual maintenance costs on fans, motors and filters.
  • Reduced noise levels with positive impact on operator working conditions.

Savings

Energy savings delivered per year: 455,000 kWh

Energy cost savings per year: A$63,700

Emissions reduction per year: 387 tonnes CO2

Conclusion

EECO2 delivered the HVAC design review, re-commissioned the HVAC system & carried out the validation testing to protocol. EECO2 then delivered the additional savings on the remaining rooms based on findings and lessons learned during phase.

Featured Companies

EECO2 (more information, website)