Beyond Green: Takeda Manufacturing Singapore’s Remarkable Journey In Sustainability

Beyond Green: Takeda Manufacturing Singapore’s Remarkable Journey In Sustainability

In an exclusive interview with IAA magazine, Mr Chew Siou Ping, Head of Engineering at Takeda Manufacturing Singapore, provides insights on the groundbreaking journey of Takeda’s role in Asia’s biopharmaceutical landscape. From the significance of their cutting-edge positive energy building to the transformative impact of Schneider Electric’s implementation, discover how Takeda is not only redefining sustainability in pharmaceutical manufacturing but also charting a course towards a greener future.

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  1. Can you provide an overview of Takeda Manufacturing Singapore’s role within Takeda, highlighting its significance as the company’s only biologics drug substance manufacturing facility in Asia? 

Takeda’s manufacturing plant in Singapore has been making bulk drug substances for the treatment of Hematology since its official opening in August 2014. As part of Takeda’s Biologics Operating Unit network, the site is the company’s only biologics drug substance manufacturing facility in Asia Pacific. The plant has also been supporting the production of one of 12 new molecular entities in Takeda’s product pipeline for the clinical phase.  The manufacturing production facility is run 24/7 by a diverse team of about 400 people across 9 nationalities. The company’s site at Woodlands supplies to 18 global markets, including the US, EU, UK, and Japan.

 

  1. Could you elaborate on the features of the positive energy building, highlighting its energy-efficient design and cutting-edge technology? 

Takeda is committed to achieving net-zero greenhouse gas (GHG) emissions in our operations before 2035. We initially aimed for the Singapore BCA Green Mark “Zero Energy Building” certification, but we outperformed our target and received the “Platinum Positive Energy Building” certification instead. This means the building produces more energy than it consumes. Below are some features of the building that help drive efficiency and sustainability:

 

Smart Building Technology

  • Lighting: Photosensors detect ambient light, and operate by dimming lighting fixtures to reduce energy consumption while maintaining brightness level. The use of light-emitting diodes (LEDs) also helps reduce maintenance costs due to their longer lifespan
  • Building Management System (BMS): Our BMS can read and monitor both water and energy consumption. The data helps us make informed decisions about our usage patterns
  • Hybrid Cooling: Use of ceiling fans in conjunction with air-conditioning for optimal thermal comfort while achieving energy efficiency
  • CO2 Sensors: The build-up of CO2 may cause occupants to feel dizzy, restless, or breathless. Data collected from the CO2 sensors enables the air conditioning system to regulate fresh air intake and improve ventilation for health benefits
  • Plug Load Monitoring: Load (consumption) from selected electrical plugs are monitored. The lighting in most rooms is programmed to switch off automatically based on data from occupancy sensors.

 

OTHERS

Solar panels

Solar panels covering an area of 1,600 sq m are installed on the rooftops of our two buildings, harnessing energy to reduce the operational carbon footprint of the Manufacturing Support Building (MSB)

 

Water Fittings

The majority of our water fittings were selected based on a 3-tick “Excellent” rating under the Public Utilities Board (PUB) Water Efficiency Labelling Scheme (WELS)

 

Green Transport

To encourage lower carbon footprint for personal transport, bicycle parking lots and electrical vehicle charging are available in our car park. We also provide communal shuttle buses to the nearest MRT train station

 

Rainwater Harvesting

Rainwater harvest tanks at our rooftop store rainwater for general use – i.e.  irrigation and flushing in toilets

 

Recycling Bins

To promote the segregation of recyclable consumer waste, plastic and aluminium  cans are located in the pantry

 

Heat Gain Reduction

Solar film is applied to our glass window panels. This allows natural light transmittance but has infrared and UV rejection to enhance the thermal comfort of the occupants. Louvre at the building façade helps reduce heat gain by reflecting solar radiation reductions and providing shade to the windows

 

  1. How has the positive energy building raised the bar for energy-efficient design and operations within the biopharmaceutical industry in Singapore? 

The positive energy building – the first in Takeda’s global network – was designed to reduce energy consumption, improve indoor environmental quality, increase occupant comfort, and utilise renewable energy systems. The Manufacturing Support Building (MSB) is an expansion of Takeda’s operations in Singapore and the first such investment by pharmaceutical manufacturing companies in Singapore. Initially aimed to be a zero-energy building, we are proud that MSB received the “Green Mark Platinum Positive Energy” certification from the Singapore Building & Construction Authority (BCA) in November 2022.

 

  1. What specific benefits has Takeda experienced with the Schneider Electric implementation, such as the 15% energy surplus and Green Mark Platinum Positive Energy certification? 

Takeda’s manufacturing building has been using the EcoStruxure Building Management System (BMS) since 2009. The ease of using the BMS and its capability moved us to deploy it for the new positive energy building as well. The BMS has enabled us to track and operate our systems based on real-time information, allowing us to analyse the data, helping us to discover meaningful insights, and identify areas of opportunities to achieve our sustainability goals. By leveraging the advantages of EcoStruxure solutions, the Singapore manufacturing facility can help drive growth, create value for our customers, and contribute to the nation’s economic efficiency, reduce environmental impact to Singapore to support both Singapore’s Green Plan and Takeda’s aspiration to achieve net-zero GHG emissions in our operations before 2035.

 

  1. Can you delve into the key sustainability features of the pharmaceutical manufacturing facility, emphasizing the utilization of the climatic machine learning algorithm, Internet of Climate (IOC), and other last-mile energy-saving essentials? 

Takeda’s Singapore pharmaceutical manufacturing facility has several key sustainability features:

  • Energy-Positive Building: Takeda’s manufacturing support building (MSB) is recognised by Green Mark Platinum Positive Energy (meaning it produces more renewable energy than it consumes).
  • Solar Photovoltaic Panels: MSB building has installed solar photovoltaic panels covering an area of 1,600 sq m, which generate >400 MWh of electricity annually.
  • Hybrid Cooling System: MSB building uses a hybrid cooling system with air-conditioners, ceiling fans, and thermal diffusers to optimise energy usage and improve air circulation and ventilation.
  • Low Heat Gain Façade: MSB building façade has been designed to reduce heat gain to the building.
  • Internet of Climate (IOC): The BMS utilises IOC, a climatic machine learning algorithm that considers outdoor weather and occupancy in MSB operations to reduce energy demand.

 

As for last-mile energy-saving essentials, we are currently pursuing initiatives such as:

  • Green energy generation: Install more solar PV to achieve at least 10% of total site electricity usage
  • Reduce scope 1 carbon emission: replace the NG boiler with an electric boiler

 

  1. Could you share insights into Takeda’s approach to remote monitoring and power management using industrial software, sensors, AI, and other disruptive technologies? 
  • Takeda’s Singapore plant has integrated sensors and industrial software for remote monitoring and power management. This tech-driven approach enhances operational efficiency, refines production, and fosters sustainability.
  • Our Building Management System (EcoStruxure from Schneider Electric) enables remote monitoring, real-time data collection from various sensors. AI algorithms software analyses this data, providing smart control and actionable insights. Sensors monitor and optimise parameters like room temperature control,  AHU cooling load, and ceiling fan speed use.
  • Online real-time monitoring system (from Petasense) facilitates predictive maintenance, detecting potential equipment failures in advance. This minimises production disruptions and optimises resource utilisation.
  • The EcoStruxure Power Monitoring Expert system uses smart meters and intelligent systems for real-time energy monitoring. AI algorithms analyse energy data, help identify opportunities for optimising energy consumption and reduce carbon footprint.
  • Process automation systems (MES and PCS7) are used for manufacturing operations. Cobot/robot technology is used in QC Lab for handling repetitive tasks, allowing human workers to focus on complex tasks.

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