ACTAVIS UK METERING STRATEGY: Effective energy monitoring solution

Actavis UK is a top 10 UK pharmaceutical company with one of the largest manufacturing sites in the UK providing a portfolio of products spanning prescription medicine and consumer healthcare brands. The Actavis Group was acquired by Watson Pharmaceuticals to create the world’s third largest generic pharmaceutical company, and uses approximately £1m of energy and water per annum at its plant in North Devon. Building services include HVAC, compressed air, steam, DHW and purified water. Energy is also used for production and packing as well as for the general office environment.

Challenge: Produce a site wide metering strategy to facilitate active energy management and ensure future energy projects can be identified, evaluated and verified

With a clear mandate from the company’s board to reduce carbon emissions, the management team at Actavis knew that it was vitally important to understand where and how energy was being used before developing any major reduction projects.

Thinking: Develop Energy Accounting Centres (EAC’s)

C3 provided a comprehensive review of the site’s manufacturing process and building services, looking at both primary resources (electricity, gas and water) and secondary resources (steam, LTHW, compressed air and chilled water). Energy Accounting Centres (EAC’s) were developed to cover both the specific areas of the manufacturing process and all major plant associated with producing secondary resources. A detailed survey was then undertaken to give Actavis a clear picture of their existing primary and sub-metering through a SANKEY diagram which highlighted gaps in the existing metering against those defined within the EAC’s.

Results: Excellent understanding of site wide energy consumers, managed and reported through business related EAC’s

With energy consumption for each EAC targeted against business activity levels and external drivers, Actavis is in a position to monitor and quickly identify any reductions in plant efficiency and take quick remedial action to minimise waste. Consumption data is also used to assess the potential of new technologies, develop robust business cases for future investments and verify savings delivered.