Another Run Ruined: Dealing with Power Interruptions

Pharmaceutical production is highly dependent on consistent access to a power supply. Any interruptions pose significant risk to production. Fluctuations or failure in power supply can lead ventilators, cooling generators, and production machines to stop. Aseptic production equipment is usually highly sensitive and operates within an extremely narrow voltage range. Should any fluctuation occur, the systems will react to changes in the pre-set limits, which could even cause production to halt, potentially leading to long-term delays. Failure of a ventilation system could lead to loss of clean room status, which can compromise the safety and efficacy of the product – and even lead to the loss of an entire batch.

It is absolutely critical for pharmaceutical production facilities to have backup power systems and contingency plans to minimize the risks associated with potential power interruptions.

Who turned the lights out?
 

Power interruptions, failures, and fluctuations in the power grid can have several causes. Power fluctuations specifically refer to the variation in voltage and power levels that occur in an electrical system. They can be triggered by influences on the grid side such as voltage peaks, grid and network failures, short interruptions – also known as micro-cuts – voltage dips, and harmonics. These can occur repeatedly and stem from faults in the upstream grid.

Power interruptions and fluctuations are also caused by accidental disruption of power cables, which can occur because of thunderstorms or construction in the surrounding area. Power interruptions, voltage spikes (overpower) and undervoltage (underpower) can negatively affect the consistent stream of power within a facility. In fact, even the smallest voltage fluctuations or disturbances have the potential to disrupt a facility. When a deviation occurs, equipment can easily malfunction, resulting in reduced efficiency or even complete shutdowns. If voltage fluctuations are frequent, a plant may experience cumulative damage to the equipment, leading to premature failure and increased maintenance costs, as well as – for a CDMO – loss of capacity for customers.

Most pharmaceutical and biotech players have some sort of backup power system in place. However, the specific system used depends on each company’s unique needs, evaluation of the challenges, and personal experiences. Supporting equipment such as smart grid sensors, automatic voltage regulators, surge protectors, and energy storage systems, such as batteries and complete power systems, all serve as an added layer of protection in the event of a power fluctuation or irregularity. There are generally two primary technologies: back-up power generators and uninterruptible power supply (UPS). Back-up power generators are more commonly known. Most hospitals, for example, use them to prevent loss of power. These systems are typically diesel engine driven generators that convert mechanical energy into electrical energy. They are not connected to the grid at all. In the event of a power failure, the unit kicks in and takes over the power supply of the plant. It does require a short window of time for the equipment to reach full operational levels, however, so while it is a reasonable solution to prevent power outages, it does not function as an uninterruptible power supply.

UPS systems are always on standby and constantly connected to the upstream grid. UPS systems come in two formats – static and dynamic. Static UPS systems usually use batteries as a backup power source. When the power supply is normal, the batteries charge through the power grid. If the power supply is interrupted for any reason, the UPS system switches to battery power to provide continuous power supply to any connected equipment. Static UPS systems are most often leveraged in smaller applications and to provide short-term coverage because of the limitations of the batteries.

Dynamic UPS systems, on the other hand, usually use a diesel generator in combination with a flywheel as a backup power source. When the power supply is normal, the flywheel is charged and stores kinetic energy. However, in the event of an interruption, the flywheel releases its stored energy to power the connected equipment. Dynamic UPS systems are typically used in larger applications and critical facilities, but can also be used for longer-term coverage because the engine can be powered by diesel.

Both static and dynamic UPS systems are designed to provide continuous and reliable power to critical equipment in the event of a power outage or other electrical disturbance. In the event of any external influence to the primary power source, the UPS systems will disconnect from the grid and take over the power supply independently until the grid’s energy flow is back to normal. The systems activate with no delay, preventing any harmful interruption, no matter how short, to the power supply.

Avoiding outages
 

When considering how to support uninterrupted power supply, a pharmaceutical or biotech company must define their individual requirements and goals. Companies should consider the following points when evaluating potential solutions:

• Location of the systems. UPS systems require a certain amount of space and a strong building foundation; such a system can weigh up to 25 tons. The equipment is also noisy and produces exhaust air, so insulation and filtering systems must be considered in lockstep.
• System type. It is important to consider the right partner that meets the power supply needs of the business processes. This partnership should meet all expectations and, in an ideal case, last for many years because these machines often operate for up to three decades.
• Cost. Beyond the initial acquisition and implementation costs, UPS systems require constant power to remain operational, as well as regular maintenance. This all comes with a cost, so it is important to forecast whether this will be feasible to maintain before making the initial investment.
• Personnel needs. Given the need for ongoing maintenance, a company should make sure it has internal experts who can be trained to operate the equipment in real time. 

In Vetter’s experience, UPS systems are a highly valuable investment that pay off tenfold when the priority is reliability and quality. To effectively mitigate risk of any power interruptions, think ahead and plan for the size, capacity and cost of UPS systems when planning future production sites, rather than trying to implement them after the fact.

In the best case, companies should familiarize themselves with all available solutions to find the right option for their unique needs, as each business brings its own requirements that may differ from another company, even in the same industry.

Power interruptions are outside the control of any company. Vetter, for example, experienced 60 power fluctuations and interruptions at its production sites in 2023 alone. But in every case, our UPS systems activated and prevented any harmful disturbance. There is no way that Vetter would choose to operate without these systems.

The damage of a power failure far outweighs the potential challenges of implementing a UPS system. Therefore, it comes down to weighing the pros and cons of all available options and recognizing that the risk of power failure is detrimental to the pharmaceutical company’s ability to operate effectively.