Medical Packaging Facility Energy Audit
Comprehensive energy audit of a manufacturing facility producing medical packaging materials, including office areas, clean rooms, production zones, and a warehouse. The project identified and prioritized energy conservation measures (ECMs) to improve envelope insulation, HVAC performance, lighting control, and renewable energy integration, with significant carbon reduction potential both with and without photovoltaic installation.
Detailed Assessment
- Energy use analysis for office, production clean rooms, and warehouse.
- Evaluation of building envelope and infiltration points.
- Review of lighting, equipment operation, and control systems.
- HVAC and clean room system diagnostics for improved efficiency.
Performance Evaluation
- Envelope upgrades: solar control window film, reflective roof coating, weatherstripping, sealing penetrations, insulating skylights.
- Lighting and control improvements: occupancy sensors, daylight sensors, and power management.
- HVAC enhancements: sensor replacements, bypass valve recalibration, pump repairs, VFD installation, and SOP development for operations.
- VOC exhaust system optimization and air curtain maintenance to reduce energy losses.
- Integration of photovoltaic panels and an Energy Management System.
Diagnostic Testing
- On-site inspection of HVAC system performance and control accuracy.
- Verification of airflow balance and temperature control in clean rooms.
- Identification of infiltration sources and verification of sealing effectiveness.
Maintenance Review
- Preventive maintenance protocols for pumps, valves, and control sensors.
- SOPs for HVAC and exhaust systems to ensure long-term performance.
- Staff training for efficient energy system operation.
System Optimization
- Balancing chilled water and airflow to reduce cooling load.
- Improved control sequencing for pumps and valves.
- Energy recovery integration on exhaust fans to reduce heating and cooling demand.
Efficiency Improvement
- Without PV: Estimated savings 57,648 kWh/year, CO₂ reduction 40,616 kg/year.
- With PV: Estimated savings 438,752 kWh/year, CO₂ reduction 309,142 kg/year.
Result: A targeted, cost-effective set of energy measures enabling significant operational savings, reduced carbon footprint, and improved system reliability for a critical clean-room manufacturing environment.