Energy efficiency without stopping production – Boehringer Ingelheim reduces consumption with smart energy analysis
Boehringer Ingelheim – Innovation and responsibility since 1885
Boehringer Ingelheim is one of the world’s leading research pharmaceutical companies. Since its founding in 1885, the family-owned company has pursued the goal of achieving real medical progress through innovations – now and for future generations. More than 53,000 employees work in the fields of human pharmaceuticals, animal health, and biopharmaceuticals. One central concern is sustainability and the responsible use of resources in all areas of the company.
High levels of energy consumption meet strict production requirements
Boehringer Ingelheim uses special vacuum pumps for leak testing in the inhaler-cartridge production process. The ten pumps with a total power of 55 kW consumed a high level of energy, even under no load. Also, due to regulatory requirements, it was not possible to modify the existing test system or to interrupt ongoing production. The goal: a precise energy requirement analysis under real conditions – without interfering with certified processes.
Contact-free measurement
Together with Phoenix Contact, Boehringer Ingelheim developed an intelligent solution for non-contact energy recording during ongoing operations:
- Measurement in real time: EMpro series energy measuring devices record the actual consumption data via terminals placed around the cables – without having to access the electrical installation.
- Data evaluation with PLCnext Technology: The analysis is performed via the EPC 1522 edge device in combination with the open PLCnext Technology automation system.
- Seamless integration: The solution was installed separately in the control cabinet and uses the existing 230 V supply – without affecting ongoing operations.
The openness of the PLCnext ecosystem enables the flexible integration of existing and future technologies and protocols such as Modbus, NodeRed, and MQTT.
Advantages
- 10% energy savings with intelligent standby control after 15 min.
- No interruptions in production or changes to the test system required
- Additional optimization potential through the discovery of leaks and over-dimensioned pumps
- Open, future-oriented system with easy extension and integration of new tools
- Reliable project partner: Phoenix Contact impresses with in-depth industry expertise, quick implementation, and partnership-based cooperation on an equal footing
Boehringer Ingelheim on the path to sustainable production
The joint energy demand analysis implemented enabled Boehringer Ingelheim to directly save 10% of energy – and to identify further potential for future optimization. Particularly noteworthy is that the solution was implemented without interfering with the sensitive production processes and meets all pharmaceutical requirements. Boehringer Ingelheim, together with Phoenix Contact as a partner and the openness of PLCnext Technology, is ideally positioned to achieve the ambitious targets of energy savings and carbon reductions by 2030.
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