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.

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