Improved Biofilm Control Helps Pharmaceutical Company Reduce Costs and Enhance Sustainability

GoalImprove microbiological control and heat transfer efficiency while reducing energy use and CO₂ emissions.

<p><!-- wp:acf/two-cols-text {"name":"acf/two-cols-text","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"blue","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a1b96b768f","block_title":"Overview","_block_title":"field_6629f36ac5d6b","block_content_clone":"","_block_content_clone":"field_662a1b96b76fb","text_list_0_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eIndustry:\u003c/b\u003e Pharmaceuticals\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_0_text_item":"field_662a1bf77d245","text_list_1_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eApplication:\u003c/b\u003e Cooling Towers / Chilled Loops\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_1_text_item":"field_662a1bf77d245","text_list_2_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eProblem:\u003c/b\u003e Pharmaceutical manufacturer experiencing biofouling buildup in cooling systems leading to increased operational costs.\u003c/li\u003e\r\n\u003c/ul\u003e\r\n\u0026nbsp;","_text_list_2_text_item":"field_662a1bf77d245","text_list_3_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eSolution\u003c/b\u003e: Improved water treatment program by installation of a filtration system and a targeted chemical treatment program including periodical cleaning for biofilm removal.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_3_text_item":"field_662a1bf77d245","text_list_4_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eResult: \u003c/b\u003eImprovements to the program resulted in $100,000 savings in addition to a 340 ton decrease in CO2 emissions.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_4_text_item":"field_662a1bf77d245","text_list":5,"_text_list":"field_662a1bb97d244"},"mode":"edit"} /--></p> <p><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Customer Challenge</h5> <p><!-- /wp:heading --></p> <p><!-- wp:paragraph --></p> <p>A pharmaceutical manufacturer in Ireland needed to improve the water treatment program and operational efficiencies at several locations. An evaluation of the first facility showed poor microbial control, resulting in reduced heat transfer efficiencies as cooling demand increased with site production. The reduced efficiency of the heat transfer equipment was causing higher energy costs and CO₂ emissions.</p> <p><!-- /wp:paragraph --></p> <p><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Recommended Solution</h5> <p><!-- /wp:heading --></p> <p><!-- wp:paragraph --></p> <p>Chem-Aqua&rsquo;s approach is to incorporate industry expertise and innovative technologies to decrease energy use, reduce CO₂ emissions, and improve the chemical treatment program monitoring and efficacy. System audits confirmed that poor microbiological control and biofouling deposits were a key contributor to poor heat transfer. Since biofilms are four times more insulating than inorganic scale deposits, a focus on microbiological control was needed to improve heat transfer surface cleanliness.</p> <p><!-- /wp:paragraph --></p> <p><!-- wp:paragraph {"className":"is-style-default"} --></p> <p class="is-style-default">As part of 360&deg; Chem-Aqua&rsquo;s Get Clean, Keep Clean&trade; Approach to bio-management, mechanical and chemical solutions were used to tackle the biofouling problem. A side stream filtration system was installed to reduce the amount of&nbsp; suspended particles and microbes contributing to the surface biofouling. The chemical program was improved by selecting biocides more suited to the system conditions. Corrosion inhibitors were replaced with technology that would not act as a potential food source for bacteria. Regular cleanings were also implemented using bioeXile^&reg;, a patented biofilm removal product that disrupts the structure of biofilm, allowing biocides to be more effective and insuring a deep cleaning.</p> <p><!-- /wp:paragraph --></p> <p><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Results</h5> <p>The enhanced treatment program improved microbiological control and supported cleaner heat transfer surfaces through a combination of optimized chemical treatment, side stream filtration, and regular biofilm removal. The approach helped improve operational efficiency while supporting the facility's energy reduction and sustainability objectives.</p> <p><!-- /wp:heading --></p> <p><!-- wp:acf/two-cols-text-media {"name":"acf/two-cols-text-media","data":{"reverse_columns":"0","_reverse_columns":"field_662b25288c9aa","option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"p-none","_padding_options":"field_6629e0d2860af","background_colour":"white","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662b250c20679","excerpt_full":"0","_excerpt_full":"field_669a2f3eb7d8c","block_title":"","_block_title":"field_6629f36ac5d6b","block_excerpt":"The corrective actions improved cleanliness of heat transfer surfaces. Chiller data showed a 30% and 7% increase in heat transfer efficiencies over a two year span on two of the chiller systems, translating to $100,000 reduction in energy expense. The reduced energy consumption had the additional benefit of a 340 ton decrease in CO\u003csub\u003e2\u003c/sub\u003e emissions, a critical operating parameter for the facility.","_block_excerpt":"field_6629f37dc5d6c","show_cta_button":"0","_show_cta_button":"field_6629f386c5d6d","use_special_button":"0","_use_special_button":"field_663af6cb5a467","block_content_clone":"","_block_content_clone":"field_662b25758c9ab","media_type":"image","_media_type":"field_662b350adaf55","image_ratio":"3/1","_image_ratio":"field_662b2dbfeab2c","media_image":7072,"_media_image":"field_662b25e98c9ae","block_media_clone":"","_block_media_clone":"field_662b35bd0ff2e"},"mode":"edit"} /--></p> <p><!-- wp:paragraph --></p> <p><em>CS2-009</em></p> <p><!-- /wp:paragraph --></p>