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Energy Efficiency and Waste Reduction Through Maintenance Optimization: A Case Study in the Pharmaceutical Industry

Author

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  • Nuno Soares Domingues

    (Instituto Superior de Engenharia de Lisboa, Instituto Politécnico de Lisboa, Rua Conselheiro Emídio Navarro, 1, 1959-007 Lisbon, Portugal)

  • João Patrício

    (Instituto Superior de Engenharia de Lisboa, Instituto Politécnico de Lisboa, Rua Conselheiro Emídio Navarro, 1, 1959-007 Lisbon, Portugal)

Abstract

The global rise in population, increased life expectancy, and heightened international mobility have escalated disease prevalence and pharmaceutical demand. This growth intensifies energy consumption and chemical waste production within the pharmaceutical industry, challenging environmental sustainability and operational efficiency. Chromatography, a vital analytical technique for ensuring product quality and regulatory compliance, can also contribute to material waste and energy inefficiencies if not properly maintained and optimized. This study applies Failure Mode and Effects Analysis (FMEA) to chromatographic equipment maintenance within Hovione’s Engineering and Maintenance Department, aiming to identify and mitigate failure risks. By integrating environmental metrics derived from Life Cycle Assessment (LCA) into the FMEA framework, a hybrid risk evaluation tool was developed that prioritizes both equipment reliability and sustainability performance. The findings demonstrate how this integrated approach reduces unplanned downtime, lowers solvent waste, and improves energy efficiency. Additionally, the study proposes a conceptual dashboard to support proactive, sustainability-driven asset management in pharmaceutical laboratories. By bridging reliability engineering and environmental sustainability, this research offers a strategic model for optimizing resource use, minimizing chemical waste, and enhancing long-term operational resilience in regulated pharmaceutical environments.

Suggested Citation

  • Nuno Soares Domingues & João Patrício, 2025. "Energy Efficiency and Waste Reduction Through Maintenance Optimization: A Case Study in the Pharmaceutical Industry," Waste, MDPI, vol. 3(3), pages 1-20, August.
    • Handle: RePEc:gam:jwaste:v:3:y:2025:i:3:p:28-:d:1729085
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    References listed on IDEAS

    as
    1. Alsyouf, Imad, 2007. "The role of maintenance in improving companies' productivity and profitability," International Journal of Production Economics, Elsevier, vol. 105(1), pages 70-78, January.
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