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.
