SUSTAINABLE ENERGY SOLUTIONS FOR PHARMACEUTICAL MANUFACTURING: ENGINEERING, IT, AND POLICY APPROACHES TO REDUCE CARBON FOOTPRINTS

Abstract

Pharmaceutical manufacturing uses a lot of energy and produces significant carbon emissions. This project explores sustainable energy options by combining engineering improvements, IT-based optimization, and policy measures. A baseline study showed the site uses 4,500,000 kWh of electricity and 2,100,000 MJ of steam, resulting in 2,670 tons of CO₂ per year and an energy intensity of 5.25 kWh per kilogram of product. Various engineering upgrades, like heat recovery systems, electric steam generation, and advanced process controls, were analyzed for cost and effectiveness. Each could reduce CO₂ emissions by 55 to 112 tons per year, and together they could cut about 40% of the target emissions. IT tools, such as Energy Management Systems, predictive maintenance, and digital twin modeling, helped improve operations by increasing efficiency by 43% and cutting electricity and steam use by 10% and 5%, respectively. Policy support, including renewable energy incentives and energy efficiency grants, increased the chances of adopting these technologies and complemented the technical solutions. Overall, this combined approach could lower CO₂ emissions by over 1,050 tons per year without affecting production or costs. The project also provides useful resources for plant managers, policymakers, and sustainability experts to help reduce carbon emissions and meet climate goals. Bringing together different fields offers the best chance to achieve low-carbon pharmaceutical manufacturing aligned with global climate targets.