Summary
Scope of the contract: Conversion of the findings from the Energy Audit into a three-tiered action plan (“quick wins, ”process improvements, andplant revamping), with the aim of incorporating it into the 2026 budget and subsequently implementing it at the plants.
Project Objective: To develop a concrete decarbonization master plan by translating energy analyses into actionable measures, resulting in a measurable reduction in energy consumption and carbon footprint, and optimizing the return on investment.
Key Information
Client Name: A leading international pharmaceutical company in the CDMO (Contract Development and Manufacturing Organization) sector .
Project Name: Integrated Energy Efficiency Program and Decarbonization Process for Three Italian Plants of the Pharmaceutical Company.
Project Period: 2024 – In Progress
Buildings involved: 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:
For a leading leading international CDMO group, Enertech Solution has implemented an integrated energy efficiency program, transforming the theoretical findings of the Energy Audit (required by Legislative Decree 102/14) into detailed implementation plans included in the 2026 Budget.
The strategy adopted for the three Italian plants of thepharmaceutical company is pragmatic and scalable, divided into three levels of technical complexity to maximize theeffectiveness of investments.
“Quick Wins” Measures (Maintenance and Adjustment)
The first step is theelimination of hidden waste in auxiliary systems, with payback periods often less than a year:
- Steam Network: in the Site 1, the mapping and replacement of the condensate drains defective will allow you to block a vapor dispersion estimated at approximately 1,300 metric tons annual, optimizing the thermal cycle plant-specific.
- Compressed Air: on Sites 2 and 3, action is taken by instrumental research of the losses and thesetpoint optimization by operating pressure, reducing theelectric power consumption of the compressors without affecting production continuity.
- Inverter Retrofitting: The use of VSDs (Variable Speed Drives) on rotating machinery, such as process fans and blowers, will allow the power consumption curve to be adjusted to the actual load demand.
Thermodynamic and Process Recovery
The second level applies the principles of thecircular economy to specific waste streams specific to the chemical and pharmaceutical sector:
- Cryogenic Nitrogen Recovery: in the Site 2 and in the Site 3, thenitrogen used for the low-temperature processes (cryogenic) will be recovered using a compression system and storage (booster + buffer). The recovered gas will replace virgin nitrogen for theinerting of tanks and the safety of afterburners.
- Sensible Heat Recovery: At Site 1, the residual heat from the boiler flue gases (currently at 130°C) will be captured using dedicated heat exchangers to preheatthe process water, thereby reducing the burners’ natural gas requirements.
Electrification and Plant Revamping
The third level addresses the process of structural decarbonization through the shift in energy sources (Gas and Electricity):
- HVAC Project (Site 2): Plans call for the decommissioning of theuse of steam for air conditioning in favor ofelectrification. Installing a Multipurpose Heat Pump will ensure thermo-hygrometric control in the various areas, eliminating a significant portion of gas consumption (Scope 1) and resolving long-standing issues related to summer comfort.
- Afterburner Efficiency Improvements: in the Site 1 and in the Site 3, the plant revamping by thermal oxidation will include theInstallation of burners next-generation and the heat recovery on wash water (scrubber), transforming a energy-intensive facility in a source of thermal energy for the plant.
From Data Analysis to Project Implementation
From data analysis to project implementation: Enertech Solution provided the client with a concrete Decarbonization Master Plan , in which sustainability is measurable in terms of energy ROI and reduction of the carbon footprint.
An approach that transformsEnergy Management from a cost center into an opportunity for technological development.
For more information about this project and the Enertech Solution method please contact our team.
Do you need counseling?
Fill out the form, and we will get back to you as soon as possible.
