baxter healthcare of pr – aibonito - newmoa · baxter healthcare of pr – aibonito for baxter...

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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


Automated Sets Assembly Capabilities

– Full Machine Shop Capabilities

– Largest Gamma Sterilizer in the Caribbean

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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


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


y p y gestablished goals.

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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


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


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%

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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


– 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


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


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:


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.

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− 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%.


− 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


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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”


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


• 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

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PREP-ROOMKETTLE WASH

1.5%DW TANKHEATER

Steam Optimization Project

STEAM SYSTEM - PREVIOUS STATE

MECO DW20%

LABORATORYAUTOCLAVE

3%

4%

CARBON

CAFETERIAHOT WATER

3%


WASTEEVAPORATOR

60%

CARBONFILTERS

0.5%

DISTRIBUTION, RADIATION, AND CONVECTION LOSSES, BLOWDOWN, AND NON-USEFUL STEAM 8%

150 Hp BOILERS


STEAM SYSTEM – OPTMIZED STATE

MECO DW

CAFETERIAHOT WATER

150 Hp BOILERS

PREP-ROOMKETTLE WASH

CARBONFILTERS


WASTEEVAPORATOR DW TANK

HEATER

BACKUP

6 Hp BOILER

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− 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


• 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


− 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,


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)

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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


• Outside light use for interior lighting

• Warehouse, Stock Room, and Conference Room

Solar Power in Baxter – Aibonito

Photovoltaic Panels

� Solar Water Heaters


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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


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.


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%

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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


gy• Occupancy Sensors installed• 162,000 kWh per year reduction• Total Project Yearly Saving: $28k

with an investment of $58k• IRR = 48%

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