HVAC Optimisation at AbbVie Ballytivnan, Sligo

This low-cost project, HVAC Optimisation at AbbVie, Sligo has shown substantial savings over 4 months.

Background

AbbVie Ballytivnan Sligo, established in 1974, is a global centre of excellence for design control and precision engineering in the production of drug delivery devices. The site has recently completed the construction of a state-of-the-art biologics aseptic fill finish facility. AbbVie is proud to be a member of SEAI’s Large Industry Energy Network (LIEN). The site received ISO 50001 certification in November 2015.  

The Project

As part of efforts to reduce energy consumption, Abbvie optimised the HVAC (Heating, Ventilation and Air-conditioning) systems. The team achieved this by increasing the humidity control to +/-10% relative humidity from the previous control of +/-1%. Modifications were made to the AHU heat recovery system to allow the system to operate in dehumidify mode. The project reduces the amount of steam needed for humidifying in winter and chilled water for dehumidifying in summer. 

Results

AbbVie completed the project in December 2023 and to date, it has had a positive result on the site’s environmental impact. In just over 4 months, the HVAC optimisation has reduced LPG usage by 55,600 litres, 18,832Kw of electricity and 136m3 of water. Overall, AbbVie has saved €34,600, reduced CO2 emissions by 95 tonnes and saved 405MWh of energy. A 12-month forecast, based on the savings to date, shows an annual saving of 156,380kWh of electricity, 294,344 litres of LPG, €210,420 cost saving and 534 tons reduction in carbon emissions.  

Next steps

AbbVie Global has set a goal for its sites to achieve a 42% reduction in carbon emissions by 2030, followed by a 95% reduction by 2040. They have set an ambitious goal to reduce carbon emission by 42% by 2028. In their efforts to attain this target and continuously improve efficiency, AbbVie Ballytivnan has planned projects which include: 

  • Replacement of 3 AHUs with the installation of heat recovery systems and energy efficient fans.  
  • Installation of a heat pump 
  • Electrification of steam 
  • Switch to renewable bio-LPG 
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