Industry Case Studies, Life Sciences

Reducing Overall Energy Costs through Utility System Analysis

Background:
Energy costs moved a Fortune 500 Pharmaceutical company to investigate the total energy conversion and distribution system within its plants. Utility usage and associated costs caused the company to pursue plans to monitor and improve the efficiency energy utilization. These initiatives were being led by the client but were largely staffed by third party services companies. As such, this leading manufacturer was looking for an integrated utility control system to support their manufacturing processes.

Situation:
The client’s primary need was for a detailed review of overall utility utilization and the energy conversion environment, leading to recommendations for the future vision of their energy plant systems along with a plan of action to achieve it. EnteGreat was brought in to leverage its expertise with all phases of manufacturing integration projects.

Solution:
The primary objectives of this project were two fold, to develop a high level view of all utilities, and to look at the individual conversion processes to assess the opportunities to increase conversion efficiencies by more intelligent control of individual units, thus allowing better coordination of all units. To accomplish these tasks, EnteGreat developed a topographic view of the utilities systems to identify all conversion systems, distribution metering and uses for electrical, gas, steam, chilled water and air systems. From the topographic view, discussions were held to assure that the utility metering system was sufficient to support the manufacturing processes, as they exist today. Modifications were suggested relating to needs for additional metering, misplaced meters, installation deficiencies, and broken meters.

The control of each energy conversion unit was fully reviewed, and better methods were suggested based on the current cost of energy. With higher cost of prime energy sources, the control methods deemed too costly for the incremental improvement in efficiency yesterday are appropriate today. With tighter control and complete monitoring, coordination of all utility subsystems was an attractive option.

Additionally, EnteGreat uncovered some governmental safety regulation compliance issues and formulated appropriate recommendations.

Benefits:
EnteGreat's contributions to this project gave the client the confidence to move forward with their utility systems upgrade program with the assurance that all aspects of the total system have been optimized. EnteGreat’s total systems view gave the client a better understanding of how their utilities plant relates to the profitability of their products and how to effectively control them.

Read more about EnteGreat's Utilities Management Solution - click here.