Dealing with sustainability in the highly regulated pharmaceutical sector is one of the biggest challenges for all stakeholders. In addition to the classic project management triangle of quality - cost - time, there is also the impact of sustainability. Data driven solutions, starting from Process via Cleanroom / HVAC until utility supply are needed on the one hand to optimize existing plants (Data from e.g. Rockwell BMS/EMS system) or setting up the new design criteria for a greenfield investment fully performance based.

The most important role of the pharmaceutical industry is to develop, produce and deliver medicines of the highest quality in the shortest possible time to improve the quality of life for people and animals around the world. This would mean, according to the Sustainable Development Goals (SDGs), that the goal of SDG 3 (good health and well-being) is sufficient for this industry. Fortunately, this industry is very active in becoming carbon neutral, implementing sustainability roadmaps in their units and investing in zero emission projects.
In a highly regulated environment such as the pharmaceutical industry, holistic and comprehensive expertise in climate strategy goes hand in hand with in-depth knowledge of GMP-compliant production, processes, cleanrooms, facilities, and energy generation.
How to reduce the energy demand of a cleanroom and providing a high contamination removal effectiveness?
This up-to-date concept does not use the “rule of thumb” of air change rates, instead generates time and space resolved data by simulation. By simulating the production process (material flows, resource utilization, capacities and timing sequences) data is generated which feeds another simulation - the airflow CFD. In other words: The output of the production simulation is the input for the cleanroom design and HVAC operation strategy. This includes time and movement resolved operator handlings, heat load generation of the equipment and batch cycles. In a next step the airflow CFD will simulate requirements for an effective air distribution in the room and consequently describing air cleanliness, particle levels, and microbial contamination. As a result, the time and space resolved reduction in air flow is highly beneficial in the areas of installation costs, running costs, energy consumption and CO2 emissions guaranteeing product safety and process robustness.
Finally, a holistic energy consumption calculation of the designed ventilation system can provide a realistic picture of the requirements for general utilities (heating water, cooling water, steam, electricity), highlighting opportunities for further reductions of energy demand.