© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. TECH GROUP EUROPE DUBLIN S.E.I. ENERGY MAP WORKSHOP 4 Keith Henderson

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Items to Cover 1.Total Energy Consumption 2.Energy Survey and Metering 3.Register of Opportunities* 4.Project Charter* – Compressed Air 5.Programme Plan *Please note that there are documents linked to these sections that must be downloaded. Please see resource box for these items.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Total Energy Consumption 12 months up until 1 st November 2006, Annual Electricity Bill – in the region of €1.2m Increase of 31% for 2007 Forecasted Electricity Bill for 2007 (assuming same consumption as previous year) - in the region of €1.6m

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Energy Survey and Metering Energy Survey carried out throughout the plant to identify areas of saving opportunity. High level metering installed to provide electricity split to Business Units. Hand held meter purchased for evaluation of individual items.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Energy Surveying

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. High Level Metering

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Energy Split per Business Unit The Effect of the Price Increase

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Hand Held Metering Examples of metering carried out so far :- Air compressor – Receiver Comparison AHU for clean room 1 – AHU 6 Shut Down Chillers – Old Tricool v new York Chiller

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Compressor Comparison Before and After Receiver Installation

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Compressed Air – Effects of Larger Receiver Installation Before receiver installation – average kW of compressor of kW After receiver installation – average kW of compressor of kW Estimated savings due to receiver installation is approximately €9,000

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Clean Room 1 - Air Handling Unit 6 Survey

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Clean Room 1 – Air Handling Unit 6 Survey Air Handling Unit Average Energy – 14.68kW Approximate Annual cost to run AHU 6 - €14,000 Weekend Shutdown Hours – 63 hours Estimated savings due to switching off AHU6 at weekends when not used €5,000 !!! Savings could be considerably higher as the AHU costs would rise during the summer months due to cooling load being increased.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Chiller Comparison

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Chiller Comparison

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Register of Opportunities Is placed in the folder P:\Energy along with other material relating to the energy saving projects. Register of Opportunities.xlsRegister of Opportunities.xls Will be incorporated into the company’s overall Lean Policy. Will be viewable, but password protected for changes and co-ordinated by Keith Henderson. Ideal scenario is to carry out a savings validation, by first measuring the usage, then measuring after project to show savings. See previous Compressed Air example.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Project Charter New standard form being created to add to QMS and Lean Charter Introduction. Project charter now produced for compressed air project. Energy Project Charter.docEnergy Project Charter.doc Project charters will be used for all projects requiring capital funding.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Projects Completed Metering installed at high level of distribution system to split business units. New Chiller installed for Business Unit 1 Process Chilled Water. Approx saving €15,000 per year Power factor correction improvements to avoid bill charges. Approx saving €10,000 per year!!!

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Projects Ongoing MIC Level increase Complete survey of all equipment in the plant. Occupancy Sensors for lighting in areas of irregular / infrequent occupancy. Compressed Air – New air receiver installed and pressure reduction program to commence. AHU Filters – New project started to find more efficient filtration in air handling units. Cooling Tower refurbished and awaiting installation of replacement variable speed drive. Clean Room 1 key-switch operation for AHU Shutdown when not in use – wired to BMS, awaiting software change.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Projects Planned Lighting load reduction throughout the plant. Lighting accounts for approx. 8% of our electricity costs. €96,000. Chilled water temperature assessment to determine optimum required temperature in each area. Envirostart units to fit to injection moulding machines. Investigation of cold water spray/evaporative humidification to replace steam humidifiers on AHU 7 and AHU 8.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. Programme Plan Programme Plan currently being drawn up as part of our company’s new lean manufacturing introduction. Separate budget to be allocated to the energy programme plan.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without written permission of West Pharmaceutical Services. TECH GROUP EUROPE DUBLIN S.E.I. ENERGY MAP WORKSHOP 4 END Keith Henderson