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1
Baxter Healthcare of PR – Aibonito
For Baxter – Aibonito Internal Use Only
Baxter Aibonito Plant Characteristics
– Started Operations: August 1976
– Work Force of 944 FTE
210 000 Square Feet Facility– 210,000 Square Feet Facility
– Vertically Integrated Facility
– 7 day, 24 hr Operation
– 169 Finished Product Codes
– Automated Sets Assembly
For Baxter – Aibonito Internal Use Only
Automated Sets Assembly Capabilities
– Full Machine Shop Capabilities
– Largest Gamma Sterilizer in the Caribbean
2
Environmental and Energy Working Group
Evet Vera Carlos Montesinos Jose Arroyo
L. LoraEngineering Director
Roberto MercadoEnvironmental Coordinator
Evet VeraEnvironmental Manager
Joaquin TraversoUtilities Lead Technician
Carlos MontesinosFacilities Manager
Jose ArroyoEnergy Manager
For Baxter – Aibonito Internal Use Only
Environmental Program Objectives
− Minimize any adverse Environmental effect or risk that our activities could have over the environment.
O r foc s ill be on poll tion pre ention reso rce conser ation and− Our focus will be on pollution prevention, resource conservation, and accident avoidance.
− Comply with Environmental regulations and policy requirements through established mechanisms and systems.
− Identify and implement the necessary changes to achieve the
For Baxter – Aibonito Internal Use Only
y p y gestablished goals.
3
Former PTRACK Goal – 4.5% reduction by 2009 from 2006 baseline
Non-hazardous solid waste generation
5.00
Former Performance Track Commitment
2009 Goal3.97 Mlbs
4.16
3 50 3.67 3 49
2.00
3.00
4.00
Millions of P
ound
s (M
lbs)
16.1% Achieved
For Baxter – Aibonito Internal Use Only
3.50 3.49
0.00
1.00
2006 2007 2008 2009
M
3,000,000
3,500,000Recycled Disposed
Waste Recycled vs. Disposed
83.5% Achieved
2,255,944
2,963,684
3,255,961
3,101,827
2,635,318
3,101,397
3,101,493
1,698,9
1,631,
1,3
1,000,000
1,500,000
2,000,000
2,500,000
lbs
of W
aste
For Baxter – Aibonito Internal Use Only
950
,689
337,675
981,380
875,066
799,063
613,686
0
500,000
2003 2004 2005 2006 2007 2008 2009
Total 2009 Recycled = 83.5% vs. Goal of 85%Last 4 months of 2009 > 85%
4
Before After
Reusable Packaging – Reduction at the Source
– Replaced– 518 Full Gaylords– 790 Half Gaylords
1308 Covers– 1308 Covers– 1308 Pallets
– 57.8% reduction in cardboard gaylords sets purchased in 2009 vs. 2008
– 93.6% reduction in pallets purchased in 2009 vs 2008
For Baxter – Aibonito Internal Use Only
– 705,288 lbs of waste not generated
– $290,194 total saving in 1 yr with a total investment $224,133.00
Former PTRACK Goal – 20% reduction in VOC emissions by 2009 from 2006 baseline
Cyclo, IPA, EA, 3M Fluid, and Loctite Adhesives
45.00
50.00
VOC Air Emissions Reduction
2009 Goal32.46 klbs
40.5820.00
25.00
30.00
35.00
40.00
Thou
sand
s of Pou
nds (klbs)
31.4% Achieved
For Baxter – Aibonito Internal Use Only
30.90 29.13 27.83
0.00
5.00
10.00
15.00
2006 2007 2008 2009
T
5
− Implemented the use of 70/30 Isopropyl Alcohol (IPA) pre-saturated wipes for equipment sanitization throughout the facility thus reducing IPA air emissions
VOC Air Emissions Reduction
− Replaced the use of IPA for parts washing in Keifel with a non-hazardous substance
− Replaced the use of thinner for ink plates cleaning with a non-hazardous substance developed under the EPA Design for the Environment Program
− Improved solvent management by providing training to Solvent Utilities
For Baxter – Aibonito Internal Use Only
personnel and establishing a log book for solvent usage per manufacturing department
− Minimized the use of Ethyl Acetate for parts washing
Former PTRACK Goal – 234 Electronic Equipment Replaced - Meeting the Electronic Product Environmental Assessment Tool (EPEAT) Criteria
250
300
350
Replaced
Electronic Equipment Replacement to EPEAT
Electronic Equipment Environmental Adverse Impact:
Goal 234
82
157214
308
0
50
100
150
200
250
2006 2007 2008 2009
Amou
nt of E
quipmen
ts R
EPEAT Equipment Benefits:
For Baxter – Aibonito Internal Use Only
1. Are very resource intensive to manufacture.2. Contain significant amounts of toxic and
environmentally sensitive materials.3. Use electricity inefficiently.4. Have a relatively short useable lifespan.5. Are inefficiently and/or ineffectively recovered and
recycled.
1. Savings in energy use.2. Savings in virgin material use (increase in
recycled materials).3. Savings in CO2/Greenhouse gas emissions.4. Savings in air emissions.5. Savings in water emissions.6. Savings in toxic materials.7. Savings in municipal solid waste generation.8. Savings in hazardous waste generation.
6
− Re-certified under ISO 14001 and OHSAS 18001 with exceeding rating.
− External audits – EQB, EPA, and PRASA without any findings.
Environmental 2009 Accomplishments
− Three (3) consecutive years without NOVs.
− All regulatory requirements successfully fulfilled.
− Non-hazardous waste generation of reduction of 16% from 2006 vs. a goal of 4.5%.
For Baxter – Aibonito Internal Use Only
− Recycling increased from 57% in 2003 to 83.5% in 2009
− VOC emission reduction of 31.4% from 2006 vs. a goal of 20%
− 308 EPEAT certified electronic equipments replaced vs. a goal of 234
Earth Week Activities – April 20097 Environmental talks given at Community Schools
EHS Community Outreach
For Baxter – Aibonito Internal Use Only
7
EHS Employee Involvement
– Activities:– Alternative Energy Exhibits– Municipality Recycling Office- Recycling Campaign– Seminar “El Huerto en tuCasa”– Extension Service Talks on “Vermicomposta” and “Sistema de Riegos”
For Baxter – Aibonito Internal Use Only
g– Recycling “Artesanos”– Trees from DRNA for adoption– Environmental Exhibits
Energy Consumption Trend
25,000,000
30,000,000
d Prop
ane)
25,331,04222,872,737
20,523,815
5 000 000
10,000,000
15,000,000
20,000,000
tal Ene
rgy Co
nsum
ption (Electric, Diesel, an
For Baxter – Aibonito Internal Use Only
• 12.8% electric power reduction (2,662,466 kWh) vs. 2007• 48% reduction (54,000 gallons) in diesel consumption vs. 2007• 19% total kWh reduction (4,807,227 kWh) vs. 2007
0
5,000,000
2007 2008 2009
Tot
8
PREP-ROOMKETTLE WASH
1.5%DW TANKHEATER
Steam Optimization Project
STEAM SYSTEM - PREVIOUS STATE
MECO DW20%
LABORATORYAUTOCLAVE
3%
4%
CARBON
CAFETERIAHOT WATER
3%
For Baxter – Aibonito Internal Use Only
WASTEEVAPORATOR
60%
CARBONFILTERS
0.5%
DISTRIBUTION, RADIATION, AND CONVECTION LOSSES, BLOWDOWN, AND NON-USEFUL STEAM 8%
150 Hp BOILERS
Steam Optimization Project
STEAM SYSTEM – OPTMIZED STATE
MECO DW
CAFETERIAHOT WATER
150 Hp BOILERS
PREP-ROOMKETTLE WASH
CARBONFILTERS
For Baxter – Aibonito Internal Use Only
WASTEEVAPORATOR DW TANK
HEATER
BACKUP
6 Hp BOILER
9
Steam Optimization Project
− Project Scope:• Optimize plant steam production according to demand• Only value adding activities should be steam consumers
E l t lt t• Evaluate alternate energy sources
− Project Results:• Reduced operation of a 150 Hp boiler from 24 hours / 7 days a week
to less than 8 hours / 3 days a week– Minimized use for water distillation only– Runtime reduction from 8400 hours to 2000 hours per year
For Baxter – Aibonito Internal Use Only
• 6 Hp boiler installed for plant’s minimal constant steam load only– Distilled water tank heater– Diesel consumption of 2 gallons/hour vs. 9 gallons/hr of the 150 Hp
boiler− Steam pressure header reduction from 100 psi to 70 psi
Steam Optimization Project
− Project Results:• Elimination of highest steam consumer
– wastewater evaporator– Sludge generation elimination
• 60% (48 000 gallons) reduction in yearly• 60% (48,000 gallons) reduction in yearly diesel consumption– 31,000 vs. 79,000 gallons.– Reduction 35,337 lbs of combustion
gases and 1,110,000 lbs of greenhouse gases
• 2010 Year to date diesel reduction vs. 2009 – 50%
• Incorporated green energy, water reuse,
For Baxter – Aibonito Internal Use Only
p g gy, ,and rain harvesting into the plant’s infrastructure.
• Total Project Yearly Saving: $145k with an investment of $220k
• IRR = 58%• Reduction of 9% total plant’s energy
consumption (1,800,000 kWh)
10
Green Energy Integration
− Rain harvesting system• 10,000 gallons capacity
S f f− Solar Heater for cafeteria hot water
− Photovoltaic cells – pilot area• 9 kW system
− SolaTubesO f
For Baxter – Aibonito Internal Use Only
• Outside light use for interior lighting
• Warehouse, Stock Room, and Conference Room
Solar Power in Baxter – Aibonito
Photovoltaic Panels
� Solar Water Heaters
For Baxter – Aibonito Internal Use Only
11
Water Reuse
− Wastewater evaporator shutdown as part of the steam optimization project.• Prep-room wastewater is being reused as cooling tower makeup
– Diluted 4:1 with fresh water from other sourcesA d 450 000 ll d– Around 450,000 gallons per year reused
– Soap elimination of 60% of total washed volume
− HVAC condensate water collection• Over 1 million gallons per year @ 50 °F• Used for cooling tower make-up
− Process chlorinated water weekly reject
For Baxter – Aibonito Internal Use Only
Process chlorinated water weekly reject• Around 100,000 gallons per year• Used for cooling tower make-up
− Re-use of MECO still reject water for boiler feedwater• 30,000 gallons per year reused
Compressed Air System Upgrade Project
− Project Scope:• Reduce air compressor’s cycling
and load• Reduce supply header pressure• Provide constant header pressure• Provide constant header pressure
and flow
− Project Results:• Accumulation tank and demand
control valve installed to respond according to plant’s demand.
• Supply header pressure reduction from 115 psi to 90 psi.
For Baxter – Aibonito Internal Use Only
p p• 15% reduction in air compressor
power usage– 609,000 kWh per year
• Total Project Yearly Saving: $109k with an investment of $110k
• IRR = 92%
12
Lighting Retrofit Projects
− Project Scope:• Reduce power consumed by
lighting fixtures• Include new energy efficient• Include new energy efficient
technology
− Project Results:• Interior, exterior, and spot lighting
retrofitted with high efficiency/low consumption fixtures – LED Technology
For Baxter – Aibonito Internal Use Only
gy• Occupancy Sensors installed• 162,000 kWh per year reduction• Total Project Yearly Saving: $28k
with an investment of $58k• IRR = 48%