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Closed-Loop Process Cooling Reduces Water, Energy Use in Pharmaceutical Manufacturing

In today’s ever-developing world, it’s essential for pharmaceutical manufacturers to operate at their best and prioritize safety.

The pharmaceutical industry plays a vital role in keeping people healthy and saving lives through its products and innovations. However, the industry also faces significant challenges, particularly in terms of water and energy consumption. Like many industries, pharmaceuticals are working hard to address these issues.

Water is the most widely used resource in pharmaceutical manufacturing. It’s essential as a starting material, an added substance, and in the processing of products.

Water Usage Challenges

Given the critical role of water in pharmaceutical production, reducing its usage is a significant challenge. Many companies are now focused on conserving water to achieve two main objectives: improving sustainability and reducing operational costs.

Cooling towers are one of the major sources of high water usage. They play a crucial role in the production of various products, including:

  • Forming tablets
  • Cooling creams and ointments
  • Sterilizing liquids
  • Batch processing

Unfortunately, cooling towers typically consume between 1 and 1.5 million gallons of water annually. This water is often used only once before being discarded, frequently leaving the plant contaminated.

In addition to their high water usage, cooling towers are also heavy energy consumers. Fans and pumps run continuously, demanding significant energy. Moreover, the contamination caused by algae, solid deposits, microbiological growth, airborne diseases, and scaling necessitates chemical treatments, further increasing energy consumption and water contamination.

The Solution: Shell and Tube Heat Exchangers

Given these issues, many pharmaceutical manufacturers are now opting to replace traditional cooling towers with more efficient alternatives, such as closed-loop process cooling systems.

Closed-loop systems offer several benefits, including:

  • Reduced water and energy consumption
  • Lower operational costs
  • Enhanced control over cooling temperatures
  • Increased profitability

These systems utilize heat exchangers and an adiabatic chamber to cool process water, which is then recirculated at the correct temperature. When temperatures rise, a cooling mist is sprayed into the air inside the chamber. This mist evaporates instantly, preventing any negative impact on the cooling process. The cooled water is then circulated through the process machines.

Up to 98% Water Savings

This technology significantly reduces water consumption by reusing water rather than discarding it after a single use. Water savings of up to 98% can be achieved compared to traditional cooling towers.

Closed-loop systems also help reduce contamination issues associated with cooling towers. The recycled water meets sanitary requirements, reducing the risk of problems like airborne diseases. Additionally, these systems lower energy consumption. In some climates, plants can even turn off chillers during colder months, further reducing energy use.

In today’s rapidly evolving world, it’s essential for pharmaceutical manufacturers to operate efficiently and safely. For these companies to remain profitable, finding ways to cut costs while reducing water and energy use is crucial.

To learn more about how shell and tube heat exchangers can enhance your operations, consult the experts at Enerquip.

 

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