Global Medical Device Manufacturer
Climeaction Case Studies
Overview
In 2023, this facility engaged Climeaction to deliver a comprehensive decarbonisation strategy for the entire site through the FAST Framework. The engagement aimed to support a 30% facility expansion while achieving a 35% reduction in Scope 1, 2, and 3 emissions.
The Challenge
The facility required a comprehensive decarbonisation strategy to address rising energy demand across a multi-building site and to progress toward its 30% energy reduction target. The FAST assessment highlighted heavy reliance on steam and gas within the Low-Pressure Hot Water (LPHW) network, as well as significant cooling loads driven by ammonia chillers and open-loop cooling towers.
Capacity limitations were a major constraint, with existing boilers already operating near minimum efficiency and unable to support future production growth. At the same time, strict planning restrictions prevented new permanent structures on-site. This meant any additional plant had to be designed for modular, offsite construction, and elevated on a three-storey frame to meet safety and space requirements.
The project also faced electrical constraints, as no available medium-voltage supply existed for the new equipment. A dedicated transformer upgrade was needed to meet the load.
The existing LPHW network combined CHP units, boilers, and multiple hydraulic circuits, creating complex integration challenges. Space limitations, safety considerations, and process-critical connections meant that a standard heat pump tie-in was not feasible without risking operational disruption.
Additionally, restricted on-site working space demanded careful coordination between design, build, and delivery teams, with modular installation used to minimise downtime and maintain production continuity.
Together, these constraints required a highly engineered solution that balanced planning requirements, operational reliability, and the need for major energy and carbon reductions.
The Solutions
Energy Efficient Design
Climeaction carried out a detailed Energy Efficient Design study in accordance with IS 399:2021. Several low-carbon heating and cooling pathways were modelled, and the optimal configuration was selected based on operational efficiency, space, and environmental performance.
Equipment
- 1 x 1.2MW Ammonia Heat pump operating @85°C
- 3 x 1.2MW Ammonia Chillers operating @5°C
- 2 x 1.5MW Open Loop Cooling Towers
- 3 x Offsite build pump skids with n+1 redundancy
- 1 x 40m3 Chilled Water Buffer Tank
- 1 x Decoupling heat exchanger on the source side of the heat exchanger (process)
- 1 x 2.5KVA Transformer
Heat Pump Tie-in and Capacity Correction
To allow the heat pump tie-in, Climeaction reviewed the hydraulic balancing and connection sequence of the LPHW network. By relocating two boiler feed pipes to the opposite header, hydraulic performance was improved, allowing for the heat pump connection and increasing overall boiler capacity by 40%.
Three story Steel structure
A three-storey steel structure was designed and fabricated offsite to eliminate the need for planning permission. The structure accommodates two chillers on the ground floor, a heat pump, chiller, electrical switch room, and pressurisation system on the first floor, and two open-loop cooling towers at roof level. Each level is safely accessible for operation and maintenance.
Offsite Construction
The heat pumps and chillers were built in bespoke modular enclosures offsite. Each enclosure consists of two transportable sections and provides full access for maintenance, operation, and eventual end-of-life replacement. This approach reduced on-site construction time and minimised disruption to production operations.
Our Results - Global Medical Device Manufacturer
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