Summary
Scope of the project: Use the data collected through the Energy Audit as a technical basis for defining an operational roadmap for a decarbonization process.
Project Objective: To transform the analysis of energy consumption into an operational action plan, structured across three time horizons and aimed at defining the 2026 Investment Plan and the decarbonization roadmap for production sites.
Key information
Client Name: A leading international pharmaceutical company in the CDMO (Contract Development and Manufacturing Organization) sector .
Project Name: Energy Audit and Development of the 2024–2026Operational Roadmap fora Leading Pharmaceutical Company in the CDMO Sector .
Project Period: 2024 – In Progress
The following were analyzed: 3 of the company’s production sites located in Italy, characterized by energy-intensive industrial processes.
Brief description of the planned activities:
Since it is classified as a company with high energy-intensive (“energy-intensive”), the pharmaceutical company is required by law to update its Energy Audit (Legislative Decree 102/14). However, the objective of the management was not limited to mere bureaucratic compliance.
From Energy Audits to the Path to Decarbonization
The company’s intention was to use thedata analysis from the Energy Audit as a starting point for defining a concrete Decarbonization Pathway.
Support from Enertech Solution has evolved from a analytical phase to a purely operational: once the phase of mapping of the consumption, we have partnered with the customer in the definition of the 2026 Budget, by developing an action plan on three time frames.
Short-Term Plan: Optimization and “Quick Wins”
The short-term short-term calls for theoptimization energy and “Quick Wins”
TheEnergy efficiency starts with optimal of of existing resources. Before evaluating New Capex; the plan calls for low-impact economic and immediate return (< 1 year), such as:
- Steam Management: at Site 1, characterized by intensive thermal processes, a massive maintenance on the condensate drains. The replacement replacement underperforming components will eliminate steam losses estimated at over 1,300 metric tons per year.
- Energy Carriers: at the Site 2 and Site 3, research instrumental leakage and the simultaneous reduction in operating pressure will ensure a significant reduction in electricity consumption for the generation of compressed air.
- Electrical Efficiency: Installing inverters on strategic equipment (fans, blowers for water treatment) will allow consumption to be adjusted according to actual demand, overcoming the inefficiencies of ON-OFF control.
Medium-Term Plan: Process and the Circular Economy
The medium-term calls for the integration of Process and the Circular Economy
At this stage, engineering focuses on recovery of energy resources that are currently wasted, through:
- Nitrogen Utilization: at Site 2 and at Site 3, the project calls for the recovery of cryogenic nitrogen, which is currently released into the atmosphere after the cooling of the reactors. Through a system of booster and buffer, the gas will reintroduced online for the tank lining and for the safety of the afterburners, by breaking down waste and procurement costs.
- Heat Recovery: At Site 1, the installation of heat exchangers on the boiler flue gases (currently discharged at 130°C) will allow for the preheating of the feed water, reducing natural gas consumption at the source.
Long-Term Plan: Electrification and Structural Decarbonization
The long-term consists oftheElectrification and Structural Decarbonization.
The decisive step toward carbon neutrality involves the technological replacement of traditional :
- HVAC Electrification (Site 2): an ambitious project to revamping calls for theelimination of steam for summer air conditioning and winter. Installing a Heat Pump Industrial Reversible Not only will it reduce Scope 1, but will also ensure a significant improvement in workplace comfort in the production areas.
- Post-Combustion System Upgrades: At Site 1 and Site 3, work will be carried out on the core components of the flue gas treatment systems, including the installation of high-efficiency burners and heat recovery systems from the scrubbers to produce process hot water at no cost.
A Reproducible Method for Turning an Energy Audit into a Strategy
The Result: The client currently does not have a simple energy audit, but rather a 2026 Investment Plan that is ready for implementation. Each procedure is validated by a point-by-point calculation of the ROI and the tons of CO₂ avoided, demonstrating how the role of theEnergy Manager is now a strategic lever for industrial competitiveness in the pharmaceutical sector.
For more information about the project, you can contact the Enertech Solution or visit the Projectspage, where Phase 2 of the decarbonization process of the pharmaceutical company.
Do you need counseling?
Fill out the form, and we will get back to you as soon as possible.
