The Pharmaceutical Industry’s Energy Cost Problem

The Pharmaceutical Industry’s Energy Cost Problem

Pharmaceutical manufacturing plants, while limited in number, still manage to spend a collective $1 billion annually on energy costs — making energy efficiency a prime target for any such complex. Fuel costs, in particular, dramatically affect pharmaceutical plants, with any spike causing a profound uptick in cost-of-operations. In the pharmaceutical industry, a massive 65% of all energy spent is directed toward HVAC costs. R&D buildings require powerful ventilation for clean rooms, fume hoods, and more; Manufacturing buildings have the same needs as R&D; Packaging and Filling buildings need high-filtration HVAC to deal with the large amounts of airborne microscopic particles that they produce; Office buildings require a large amount of space heated, cooled, or simply ventilated; and Warehouses require a large amount of space heating, and often also require refrigeration. Another 10% goes to lighting, and the remaining 25% is divided predictably, with R&D and Manufacturing using more to power the variety of centrifuges, incubators, sterilizers, microscopes, and so on, and warehouses using the least.

Fuel Use vs. Grid Electricity

CHP is, indeed, significantly more efficient for most pharmaceutical plants than standard power use — saving nearly 50% on total energy costs…but it is not without significant problems. The most obvious of which is that generators create energy that is, to put it mildly, less than ideal for the use of the appliances attached to them. Without getting overly technical, every source of energy provides a specific waveform — ideally, a smooth sine wave that moves up and down at an even rate around the zero point. Even grid power, by the time it reaches your facility, almost always has fluctuations that can cause problems in sensitive equipment. Generator power is significantly less ‘clean’ than grid power, straight out of the box. What does that mean to you? In short, it means that every piece of equipment attached to that generator suffers from: Excess heat production (which can affect your cooling costs) Shortened lifespans (which means higher repair and replacement costs) Data loss in devices using phone or internet lines to transfer information Malfunctions in electric motors or other equipment relying on electromagnets …to a degree much greater than they would on grid power.

Automatic Voltage Regulation: Not a Solution

Most CHP cogenerators are equipped with AVR units — ‘automatic voltage regulation’ devices — and the manufacturers of these devices insist that AVR units take care of the problems generator power creates. They do, to a degree: an AVR unit does prevent a primary-power generator from creating voltage spikes, surges, sags, and drops, all of which are even more damaging than malformed voltage waveforms…but they completely fail to address the waveforms themselves. You could compare an AVR to having a backup generator ready to be turned on in case the power drops — whereas the product Linsyx Energies offers is like having a USP on-hand that kicks in automatically and instantly to provide zero gap in power coverage. That product is called the EnergyMoneySaver. p>

The EnergyMoneySaver in Pharmaceutical Applications

Linsyx Energy’s core product, the EnergyMoneySaver, gives you every tool you need to absolutely maximize your facility’s power efficiency. A powerful monitoring system that can accept input from hundreds of sensors, from motion to photovoltaic to voltmeters and many more, An equally powerful computer that can be programmed to respond to those sensors, scheduled events, other programs, manual controls, or even commands given via Internet portal or eMail. And a top-of-the-line power conditioner that resculpts the waveforms of all of the electricity coming out of your generators, causing every electric device you use to last longer, use less electricity, and send data with less packet loss. In short, the EMS will give you every tool you need. You’ll save money automatically by providing every one of your sensitive electrical devices, from the centrifuges to the data servers, with exactly the right voltage waveforms. You’ll save money after a one-time setup by being able to program precisely when certain devices or entire circuits, from lighting to HVAC and beyond, should be active, should be on standby, and should be entirely off. And you’ll save money on-the-fly as you take advantage of the capacity to log into your facility’s EMS from any wireless connection and direct specific changes to the way power is being used. With the EMS in place, and a full-scale basement-to-rooftop energy audit by our experts helping show you how to use it for your maximum advantage, we guarantee a 15% drop in the energy bills at each facility using it. How quickly will that pay itself off at your building?