Case Study
Pfizer Manufacturing Facility Reduces Energy Consumption and Carbon Emissions with Ever.Ag’s Energy ManagerAt a Glance
| Customer: | Pfizer |
| Industry: | Pharmaceutical |
The €2 billion Pfizer Grange Castle (GC) Facility in Ireland is one of the largest integrated biopharmaceutical campuses in the world. It is the only facility in Europe to manufacture biopharmaceuticals, pharmaceuticals and vaccines within the same facility. Consisting of multiple manufacturing suites, bulk drug substance production, warehousing, QA/QC laboratories, and a complete pilot lab facility, the Pfizer site is one of the largest energy consumers in the country and within the Pfizer organization.
Challenges
Pfizer GC required a sustainability solution that would enable them to identify, monitor and target the largest energy consuming operations at the facility. They looked to engage in energy reduction projects to reduce their overall consumption and carbon emissions. The management team was tasked with reducing the energy spend by €1 million in the first year of the reduction program, saving millions of tonnes of CO2.
Challenges
Pfizer GC required a sustainability solution that would enable them to identify, monitor and target the largest energy consuming operations at the facility. They looked to engage in energy reduction projects to reduce their overall consumption and carbon emissions. The management team was tasked with reducing the energy spend by €1 million in the first year of the reduction program, saving millions of tonnes of CO2.
Pfizer needed an efficient path to plant-wide energy intelligence, achieving the following:
Identify significant energy users
and energy flows at the facility.
Target low-cost, short-term
energy projects for immediate impact.
Continuously monitor, review and track
energy usage and savings made.
Reduce energy consumption
by 15% over five years.
With the unique Energy Manager technology, Pfizer could:
Compile complete energy maps
for all WAGES from building level to individual process equipment.
Leverage existing infrastructure
and data sources such as OSI-PI, Delta V, Schneider and Honeywell.
Backfill historical energy data,
removing the need to wait several months for a new meter to collect it.
Grow the system modularly,
allowing for the targeted analysis of energy users.
Gain quick wins
on energy savings project.
Ever.Ag Solutions
Pfizer selected Ever.Ag’s Energy Manager solution with its patented virtual metering platform. By leveraging this technology, the facility achieved comprehensive monitoring capabilities with significantly lower investment and a much faster implementation timeline than traditional metering approaches. The Energy Manager platform, utilising existing data sources such as the Process Control System, BMS, Electrical and Historian System, was implemented with zero downtime and no new hardware installations.
Ever.Ag Solutions
Pfizer selected Ever.Ag’s Energy Manager solution with its patented virtual metering platform. By leveraging this technology, the facility achieved comprehensive monitoring capabilities with significantly lower investment and a much faster implementation timeline than traditional metering approaches. The Energy Manager platform, utilising existing data sources such as the Process Control System, BMS, Electrical and Historian System, was implemented with zero downtime and no new hardware installations.
By leveraging existing meters, the Energy Manager solution was deployed to the facility over only a few weeks. The Energy Manager quickly identified users, processes and operational activities that could be changed efficiently to kick off the reduction program. The quick wins generated momentum and savings to tackle larger-scale projects.
Projects
Using the information provided by the Energy Manager platform, Pfizer GC could confidently engage in energy reduction projects ranging from significant scale capital expenditure to low- / no-cost system and work practice changes.
A small example of the proposed projects are:
Wastewater Reduction
Saving over 500m3/day
Cooling Tower Optimization
Saving over €200K/year
CIP Optimization
Saving over €300K/year
HVAC Control
Saving over €300K/year
Results
The results achieved by Pfizer GC clearly show the benefits of using the Energy Manager platform instead of a traditional metering solution. Early successes include:
A reduction of over €500K in capital expenditure compared to alternative systems.
Zero plant downtime for installing and configuring the Energy Manager platform.
Identify inefficient processes, operational activities and equipment using excessive energy within weeks of the Energy Manager deployment.
The Energy Manager platform now provides Pfizer GC with a targeted analysis toolset that is
easily expanded upon. With weekly energy usage reports, management keeps an active view of
the facility in their standard facility business meetings.
Looking Ahead
Since their program started, Pfizer GC is on target to achieve over a 15% reduction in energy usage and carbon emissions. The facility also achieved ISO 50001 certification for energy management, with the Energy Manager platform a driving force behind the monitoring and analysis required.