Brazil. Johnson Controls participated in a new success story for the Boehringer Ingelheim plant in Campinas, São Paulo, one of the world's leading pharmaceutical brands headquartered in Germany and operating globally with 176 subsidiaries and more than 50,000 employees.
In this project the challenge was focused on the recovery of the systems and operational improvements of the plant. In four years of maintenance contract, Johnson Controls said it has managed to recover the HVAC equipment in critical operation and guarantee stable operation in 98% of the equipment.
The plant suffered a failed operation in its maintenance for the air conditioning systems, so they resorted to looking for other solutions to this problem. The plant, composed of four facilities for the manufacture of veterinary pharmaceutical products, exports 90% of its products and was in a critical situation, suffering direct impacts on its internal compliance requirements with important regulations, such as the SGA.
Special plant control requirements for this operation included:
∙ Temperature control
∙ Humidity control
∙ Pressure control
Solution
Due to emerging needs, the brand signed an O&M (operation and maintenance) contract, where at first Johnson Controls worked on the recovery of the initial condition of the equipment, then worked on a preventive maintenance plan to maintain its ideal condition, and now, after 4 years of successful maintenance work, The scope was extended to predictive action.
Currently, there is a team of 20 resident employees, assigned at the Boehringer plant, which includes technicians and a supervisor to support 24/7 operation and identify other actions important to the full operation of the customer.
In an interview with Tomas Rebouças, Maintenance Manager of the Boehringer plant in Campinas, comments: "In addition to reducing technical unavailability, the team has supported us on other fronts, such as safety, since there are no records of accidents involving Johnson Controls employees; costs, control and compliance with the budget as established; quality and processes, with the completion of documentation, Johnson Controls supports us in regulatory issues involving pharmaceutical production, in addition to full-time service quality."
As a result, Boehringer has entrusted Johnson Controls with part of its sustainability actions, and new projects and investments in digital solutions to reduce gas emissions and achieve Net Zero are planned for the future.
Results
Today, Johnson Controls claims to maintain 98% availability of all equipment. In terms of sustainability, the brand explained that it has managed to minimize air exchange in production environments, reduce the energy consumption of chillers and prevent leaks in air conditioning ducts.
