a Novartis company

Londrina PR – Brazil

2012 Latin American HSE Conference

Cambé’s Site Energy Experience

a Novartis company

Alex de Paula, Gabriel Gimenes, Marcelo Costa

March 19-21, 2012 – São Paulo, Brazil

This initiative is part of SPA Program

2 | CIGE | 2011

Welcome to Cambé SiteStart up 2004

Capacity: 1,4 b bulk units/ 65 m pack units

Total Built Area: 32.165 m2

Total Land Area: 294.155 m2

ComOps

QC, QA, Eng., Supply, HSE, HR

Hormonal Bulk

RegularBulk

HBWLogistic

Packaging

Utilities/ Infra

3 | CIGE | 2011

2011Overall Results and Consumptions

Water

(-2,6%) 32.004 m³

Diesel

(-70%) 55,5 GJ1.500 l

LPG

(+17%) 5.718 GJ

115.750 kg

Electricity

(+2,7%) 23.712 GJ

6.587.319 KWh

Energy: ACT 2011 vs. TGT: - 309 GJ (- 1,1%)Volume Processing (bulk units): ACT 2011 vs. PY 2010: + 24,5%

4 | CIGE | 2011

Performance Management KPIs awareness increase PMP objectives

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Performance Management Action Plan through PDCA methodology

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• Reduce surge occurrences when external temperatures under 20oC due to high TR capacity of chillers

Key benefits:• Minimize operational and

maintenance issues• Avoid Capex with new lower

capacity chillers

• Room for energy improvement (on evaluation after chillers revamping implemented)

Energy Projects 2011Chillers Logic Implementation

7 | CIGE | 2011

1) Chillers:• Refurbishment of condensers tube• VSD installation (1 chiller)• Revaluation of primary looping to run chillers according to design parameters

Implemented in Dec/11Results: In the past, only one chiller could run during external higher temperatures and humidity (e.g. rainy days). Current situation both chillers are running and energy efficiency under evaluation.

Energy Projects 2011Chillers Refurbishment and Lighting Efficiency

2) Lighting:

24000 h33200250 WNAV-250WFuture

HQI-T400W

Type Power Lúmen Vida útil

Existing 400 W 35000 12000 h

2.1) External areas:

Implemented in October 2011.

24000 h17000150 WNAV-150W

HQI-T250W

Power Lúmen Vida útil

250 W 20000 12000 h

2.2) Internal areas:

Partially implemented in 2011.Due date June 2012

metallic

sodium

Future

Type

Existing metallic

sodium

8 | CIGE | 2011

Energy Projects 2011On-line Electricity Monitoring• Implemented on-line electricity

monitoring in order to be compliant with “Corporate HSE Guideline 14: Energy Standards for Buildings and Equipment”

• Understand electricity consumption profile and react accordingly.

• System under commissioning

First results:• Estimations are useful!• ...but might generate

misleading information when detailed analysis must be performed.

Rough estimations prior to system implemented

9 | CIGE | 2011

Energy Challenging 2011Wastewater Treatment Plant

CAR Amount:USD 1,87mTreatment flow design: 3.525 m³/month

Applicable requirements from GL14 identified and to be reviewed on basic design: monitoring energy consumption, lighting system and efficiency of motors.

Natural light in the new building

10 | CIGE | 2011

1) (Implemented) Scheduling of sanitization of 2 water storages tank after full utilization (twice a year): ~ 121 m³

2) (SOP under discussion with HSE) Scheduling of sanitization of 1 dedicated water storage tank after firefighter staff training (once a year): ~ 144 m³

3) (Implemented) Water storage volume of toilets reduced from 12 l to 6 l: ~ 600 m³

4) (Implemented) Limit water flow in 120 taps: ~ 900 m³

Water Projects 2011

11 | CIGE | 2011

Awareness 2011“Turn off the lights” campaign

Turn off the lights when leaving the room!Save Energy: Sandoz and the Planet thank you

12 | CIGE | 2011

Awareness 2011Communication

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Cambé Energy TGT 2012

Volume Processing (bulk units) :

TGT 12 vs. PY 2011: + 12,5%

14 | CIGE | 2011

1) Air Compressors replacement with 2 new compressors with VSD, oil-free design and reduced lower power capacity Investment: on evaluation Potential savings: on evaluation

Business Case Due date: May/12Responsible: Wagner (Utilities) and Eder (Projects)

Energy Projects 2012

2) Replacement of motors to fullfill the Corporate HSE Guidance Note 14.2 Technical Specifications on Buildings and Equipment Investment: on evaluation Potential savings: on evaluation

Due date: August/2012Responsible: Alex (Utilities)

15 | CIGE | 2011

Corrective Action: Steam leakage correction

Energy Projects 2012On-line LPG consumption monitoring• Implement on-line LPG consumption within electricity monitoring system in order to increase

data accuracy and reduce response time (reaction time)

16 | CIGE | 2011

2) Christ PW system: Water Recovery from RO

Water Projects 2012

3) On-line Water consumption monitoring in order to increase data accuracy and reduce response time (reaction time)

1) Blowndown efficiency increase of cooling water system: implementation of NALCO 3D TRASAR technology in order to introduce real-time monitoring, actives based control technology, stress resistant chemistry and 24/7 information management capabilities to detect, determine and deliver improved scale, corrosion and microbiological performance.

Investment: noPotential savings: system implemented, trend on evaluationDue date: Mar/12 Responsible: Wagner (Utilities)

Due date: business case Apr/12 Responsible: João and Wagner (Utilities)

Investment: on evaluation Potential savings: : ~ 145 m³ per month

Due date: August/12 Responsible: Alex (Utilities)Investment: on evaluation Potential savings: on evaluation

17 | CIGE | 2011

QUERIES ?

...and warm thanks to Josef Postl for his continuous support!

Thanks for your patience...