1. Practical Applications of Sustainability in
Biopharmaceutical Plant Design
Picture: Centocor: Project BioCork, Ireland
ISPE Facility of the Year 2009:
Category Winner: Sustainability

2. PM Group
The largest life sciences focused A&E Design & Project Management firms in Europe
1,700 people – Gross Revenue €200M
Specialising in Bio Pharma Project Delivery
Permitting & Architectural &
Full Service Company Environmental
Project
Management
Engineering
Design
o Architecture & Engineering
Consultancy
o Permitting & Environmental Consulting
o Procurement & Contract Administration
o Project & Construction Management
o Commissioning & Qualification
Privately Owned Procurement
& Contract
Commissioning &
Qualification
Established 1973 Administration Construction
Management

3. Contents
Introduction
Sustainability Defined
Sustainability Assessment Schemes
Application of Sustainable Design
Sustainable design of biopharmaceutical facilities
Andy Rayner
Group Technology Director
PM Group
andy.rayner@pmg.ie

4. What is Sustainability
Environmental Sustainability – is defined as the ability of the environment to continue to
function properly indefinitely. The goal of environmental sustainability is to minimize
environmental degradation without using the resources faster than they can be replenished
1987 Brundtland Report

5. Sustainability Assessment Schemes
LEED (Leadership in Energy and
Environmental Design) 26 Sustainable Sites
US Green Buildings Council (USGBC) 10 Water Efficiency
– Green Building Rating System
LEED 2009 for New Construction and Major
Renovations
35 Energy & Atmosphere
Otherwise known as LEED version 3.0
Ratings: 14 Materials & Resources
Certified (40-49)
Silver (50-59)
15 Indoor Environmental Quali
Gold (60-79)
Platinum (80 points and above) 100 TOTAL
6 Innovation & Design Proces
4 Regional Priority
110 TOTAL

6. Sustainability Assessment Schemes
BREEAM (Building Research Establishment
Environmental Assessment Method)
BRE (Building Research Establishment
– introduced scheme in the UK)
BREEAM: INDUSTRIAL, BREEAM: BESPOKE,
BREEAM: INTERNATIONAL
BREEAM assessments can be undertaken for both
new build and existing building refurbishment
Ratings:
Pass (30-45)
Good (45-55)
Very Good (55-70)
Excellent (70-85)
Outstanding (>85)

7. Other Sustainability Assessment Schemes
NOTE: ABOVE USES LEED V2.2 SCORES

8. Carbon Footprinting & Zero/Low/Neutral Carbon Facilities
Carbon Footprinting standards:
ISO 14064-1: Specification with guidance at the
organization level for quantification and reporting of
greenhouse gas emissions and removals
The Greehouse Gas Protocol Initiative
Corporate Standard
Project Protocol
Zero Carbon, Low Carbon & Carbon Neutral:
A zero carbon development is one that achieves
zero net carbon emissions from energy use on site,
on an annual basis
Industrial production facilities achieving zero
carbon unlikely in the near future, some residential
and commercial buildings are achieving zero carbon
today
“Low Carbon” & “Carbon Neutral” is feasible today

9. Some Focus Areas for Sustainable Design
Innovation Sustainable Energy & Water Materials & Indoor
Sites Atmosphere Efficiency Resources Environmental
Quality

10. Typical Greenfield Cell Culture Site Utility Usage
POWER WATER GAS
4.2 MVA 720 M3/DAY 1,010 NM3/HR
2 x 15,000L bioreactors
Incl. USP + DSP
1 x 1,000L Pilot Plant
Labs, Admin, CUB
Site Infrastructure
WASTE WATER SOLID WASTE
631 M3/DAY <200 TONNE/YR
Innovation

11. Typical Greenfield Cell Culture Site Utility Usage
POWER WATER GAS
4.2 MVA 720 M3/DAY 1,010 NM3/HR
2 x 15,000L bioreactors
Incl. USP + DSP
1 x 1,000L Pilot Plant
Labs, Admin, CUB
Site Infrastructure
WASTE WATER SOLID WASTE
631 M3/DAY <200 TONNE/YR
Innovation

12. Possible Disposables Implementation
Available – Good Application
Available. but must confirm process suitability
Available. but must confirm process suitability
Unavailable at larger scales
Innovation

13. Typical Greenfield Cell Culture Site Utility Usage
POWER WATER GAS POWER WATER GAS
4.2 MVA 720 M3/DAY 1,010 NM3/HR 1.9 MVA 64 M3/DAY 160 NM3/HR
2 x 15,000L bioreactors 12 x 2,000L disposable bioreactors
Incl. USP + DSP Incl. USP + DSP
1 x 1,000L Pilot Plant 1 x 1,000L Pilot Plant
Labs, Admin, CUB Labs, Admin, CUB
Site Infrastructure Site Infrastructure
WASTE WATER SOLID WASTE WASTE WATER SOLID WASTE
631 M3/DAY <200 TONNE/YR 54 M3/DAY <200 TONNE/YR
Innovation

14. Sustainable Sites
Site Selection
Development Density
Brownfield
Redevelopment
Alternative
Transportation
Site Development
Stormwater Design
Heat Island Effect
Light Pollution Reduction
Sustainable
Sites

15. Energy & Atmosphere
Commissioning of
Building Energy Systems
Optimized Energy
Performance
Refrigerant Management
On-site Renewable
Energy
Measurement &
Verification
Green Power
Energy &
Atmosphere

16. Some Renewable Energy Options
On Site Wind Power
Typical >18 year payback on Wind Turbines
Turbine Size typically 0.2kW to 10kW
Typical Offices/Laboratories Energy Usage 200,000 kWhr/yr
Example above needs 20 off 10kW Wind Turbines
Concerns over noise and takes up valuable real estate space
Height requirements can mean visual impact concern for planning
applications
Ducted wind turbines may overcome the visual concerns in future
by putting turbines inside buildings
Off Site Wind Power Options – Green Energy
Purchase power from a renewable energy provider
Good option where available – consider during site selection
Energy &
Atmosphere

17. Some Renewable Energy Options
Solar Power
Passive Solar Architecture
Consider the Building Orientation on the site
Significant solar gain issues can be minimised
Solar Photovoltaic Power Panels
Example : Google Headquarters – 9,000 solar panels gave
1.6MW which was 30% of peak power demand
Example : Payback was 7 years, but included a grant
Solar Collector Water Heating
Consider this approach for some of the hot water duties
Payback against electric and gas hot water generation is good
Energy &
Atmosphere

18. Some Renewable Energy Options
Biomass & Biofuels
If a carbon source is combusted to release carbon dioxide,
then the re-growth of that carbon source will reabsorb the
carbon dioxide – net carbon emissions effectively zero
Biomass – solid fuels capable of combustion
Examples: wood, agricultural waste, living cell materials
Biofuels – Liquid versions of biomass
Examples: ethanol, methanol, methane, hydrogen
Example of Biomass in a Biopharmaceutical Facility
Biomass boiler to handle base load heating (2MW)
Supplemental to a traditional gas boiler run on demand
for peak demand or if biomass (wood chips) supply issues
Supplier has stock close to site & delivers to onsite silo
Payback CO2 emissions reduced by 88%, but 1 extra boiler
Energy &
Atmosphere

19. Hot and Chilled Water Sources, Storage and Distribution
Geothermal Heating Systems
Where geothermal conditions permit hot water can be
obtained through geothermal closed loop systems
Concrete Thermal Slabs
Use of concrete slab thermal capacity for heating and
cooling
Can use relatively high water temperatures for cooling,
and low water temperatures for heating
Chilled Beams
Active chilled beams reduce the traditional air
conditioning requirements for offices
Energy &
Atmosphere

20. HVAC & Building Services Energy Usage
HVAC/Building Services
Primary energy users are - Fan Power, Heating, Cooling
and Dehumidification
Fan Power is the biggest energy user, limit the motive
power per m3 of air during the design to save energy and
use direct drive fans with VSD (most energy efficient)
Reduce air change rates, example:
ISO 7 – use 30 ac/hr instead of 40 ach/hr
ISO 8 - use 15 ac/hr instead of 20 ac/hr
Consider primary air handler (to dehumidify by cooling)
& a secondary air handler (to trim temperature) of fresh
(20%) and recirculating (80%) air – saves energy overall
Widen acceptable humidity bands to reduce
humidification loads
Energy &
Atmosphere

21. Centocor Example - Sustainable Energy Engineering
Do NOT deploy Renewable Energy Technology to a ‘Gas Guzzling’
Facility – THIS IS NOT SUSTAINABLE!
Begin with Energy Efficiency – Minimise the facility and process
Energy Demand
Then deploy Renewable Energy
In their totality, Energy Efficiency measures reduce Capital investment

22. Centocor - Energy Efficient Design (EED)
Application of extensive J&J Corporate Guidelines
Centocor Focus Areas During Design
Cleanroom HVAC
Offices Air Conditioning
HVAC Heat Recovery
Lighting Management
Clean Utilities
Waste Water Treatment
Black Utilities

23. Centocor - Illustration of EED Approach – Cleanroom HVAC
AHU Options Annual Cost
500,000 Centocor
450,000
Base Case Primary /Secondary
Air handling
Reduce Air
400,000
Change Rates
350,000 Reduce Specific
300,000
Fan PowerWiden Humidity
Control Bands
Cost €/year
Fan
250,000 Cooling Energy
Boiler
200,000
150,000
100,000
50,000
0
Option 1 Option 2 Option 3 Option 4 Option 5

24. Lighting
Lighting
Lighting is a large energy consumer in the
manufacturing space
Occupancy –vs- Lighting Strategy
Assess the various plant areas to determine
frequency of occupancy
Warehouse, plant room areas, and even some
manufacturing areas can have low occupancy
In low occupancy areas consider occupancy sensors to
switch light down to a minimum level when unoccupied
Light Pipes
Consider Light Pipes (rather than artificial lights) to
bring natural light into warehouse and plant rooms
that wouldn’t be directly adjacent to outside locations
Energy &
Atmosphere

25. Laboratories
Fume Hoods & Laboratory Airflow
Combination Fume Hood Sashes
Variable Air Volume (VAV) Systems
Night time Setbacks
Ductless Fume Hoods
Laboratory Waste Treatment Systems
Chemical vs Autoclave treatment
Laboratory Furniture
Low / no VOC finishes
Mobile casework increase flexibility & reduce furniture
Energy &
Atmosphere

26. Utility Energy Usage
Water For Injection (WFI)
One of the biggest utility energy users, multi-effect vs Vapor
Compression Stills
Focus on distribution temperatures – don’t run loops too
hot – run at close to 80ºC, not 95ºC
BioKill (by Heat)
Another energy intensive operation, consider minimum
temperatures – avoid excessive safety margin
Utility Redundancy
Photos coutesy Steritech
Many people operate 2 off 75% utility systems, not always
efficient at the normal base load
Consider alternative strategy of 2 off 66% + 1 off 53%
This is usually a more efficient mode of operation
Energy &
Atmosphere

27. Water Efficiency
Water Efficient Landscaping
Rainwater Harvesting
Stormwater Management
Innovative Wastewater Technologies
Membrane Bioreactor (MBR) Waste Water
Treatment System
Smaller footprint and cleaner waste
Water Use Reduction
Highest Efficiency (90%) Reverse Osmosis (RO)
Membranes to reduce waste water
Water
Efficiency

28. Materials & Resources
Storage & Collection of Recyclables
Materials Reuse
Recycled Content
Construction Waste Management
Building Reuse
Regional Materials
Rapidly Renewable Materials (eg Bamboo)
Certified Wood
Materials &
Resources

29. Indoor Environmental Quality
Outdoor Air Delivery
Monitoring
Increased Ventilation
Construction Indoor Air
Quality Management Plan
Low-emitting materials
Indoor chemical &
Pollutant Source Control
Controllability of Lighting
& Thermal Comfort
Daylight & Views
Indoor
Environmental
Quality

30. What can be achieved? – Example 1 Centocor BioCork
Centocor BioCork Project achieved
performance metrics against
benchmark sites as follows:
40% more energy efficient
97% smaller carbon footprint
Significantly smaller waste
streams