29% Energy Cut in Compressed Air System

Compressed air is a key utility for all Pharmaceutical manufacturing sites, consuming a considerable amount of electricity. Our UK-based client, part of an FTSE 100 company, was no exception. The existing air dryers used compressed air for desiccant regeneration, accounting for around 15% of total site usage. The client sought a more efficient solution amd required zero disruption to production or product quality.

Projective was engaged to review the system and recommend a solution that would reduce energy use, maintain reliability and meet strict operational constraints.

Projective identified that steam-heated air regeneration offered the most efficient and reliable alternative. Working closely with production and utility teams, we ensured the new system could be implemented without affecting operations or compliance.

The project was fully engineered and managed by Projective, with a focus on seamless integration, performance assurance and measurable outcomes.

Key focus areas included:

• Compressed air system performance review
• Engineering and integration of steam-heated regeneration
• Reduced impact implementation during live production
• Validation of carbon and cost savings
• Collaboration with site teams to ensure operational continuity.

Projective engineered and implemented a steam-heated air drying system to replace the site’s compressed air regeneration setup. This targeted intervention significantly reduced the facility’s compressed air demand, enabling the permanent shutdown of one compressor. The result was a major cut in energy use and carbon emissions.

Delivered on time and within budget, the project was executed with zero disruption to production or product quality. The results are clear and measurable:

• 29% reduction in compressed air and electricity usage
• £130,000 in annual cost savings
• 1,080 tonnes of CO₂ emissions eliminated each year.

This project exemplifies how smart engineering choices can unlock powerful outcomes. By rethinking a single utility system, Projective delivered a solution that enhanced environmental performance while strengthening operational efficiency.

Sustainability and performance can be engineered to work together, driving resilience, savings and a reduced footprint.