1. PROCESS ENGINEERING BACKGROUND

Within high-standard pharmaceutical manufacturing and chemical consumer goods production, thermal precision dictates product stability, chemical reactivity, and facility environment safety. Processing sensitive hygiene, health, and home formulations requires absolute thermal baselines rather than extreme heat spikes. Consequently, industrial Air-to-Water Heat Pumps (AWHPs) serve as optimal thermal drivers where highly repeatable, tight temperature boundaries are mandatory across multiple processing lines.

1.1 Advanced Humidity Control & Clean Room Regulation

Pharmaceutical and precise chemical packaging spaces operate under stringent regulatory guidelines regarding atmospheric moisture. The manufacturing sequence incorporates specialized dehumidification and subsequent reheating loops: 

• Deep Moisture Extraction: Primary Air Handling Units (AHUs) chill incoming air 
   below its dewpoint to condense and extract ambient water vapor, leaving the air 
   exceptionally dry but uncomfortably cold for clean room stability. 

• Thermodynamic Reheating: The air must be rapidly reheated to precise ambient 
   standards before distribution into sterile manufacturing spaces. Employing stable
   hot water loops for this reheating phase prevents rapid room-temperature 
   fluctuations, protecting hygroscopic powder formulations from clumping and 
   preserving environmental stability.

1.2 Reactor Thermal Management & Pre-heating Systems

Beyond atmospheric control, internal product formulations rely heavily on targeted water temperatures to drive safe chemical synthesis and fluid movement:  

• Endothermic Reaction Maintenance: Fine chemical reactions require steady
   thermal inputs to break molecular bonds and form stable active compounds.
   Delivering highly stabilized, non-fluctuating hot water loops to jacketed glass or
   stainless-steel reactors prevents localized hot-spots that could cause product
   thermal degradation. 

• Distillation Pre-heating: Raising liquid feed temperatures to strict thermodynamic
   ranges before entry into fractionating columns significantly minimizes internal
   column thermal shocks and optimizes energy balances within downstream  
   distillation processes.

2. TECHNICAL FACILITY OVERVIEW: RECKITT

Reckitt, a prominent global leader in consumer health, hygiene, and nutrition, enforces rigid carbon reduction and energy efficiency initiatives across its processing infrastructure. Pre-existing facility architecture utilized a centralized, carbon-intensive, diesel-fired hot water generator to maintain process heat across the facility's various production loops. To eliminate the volatility of fossil-fuel logistics, reduce localized exhaust emissions, and drastically lower high operational expenditure (OPEX), the engineering team successfully executed a full-scale thermal migration. The facility completely decommissioned the diesel-fired hot water generator, replacing it with a localized, multi-unit industrial heat pump array.

PROBLEM STATEMENT

•       Reckitt Benckiser (India) Pvt. Ltd. had a Diesel fired boiler to heat the DM
         water up to 75 deg. C for manufacturing Dettol Liquid Soap.

•       The Diesel fired boiler is used for heating water indirectly through the PHE.

•       However, this process was

•       Very Expensive

•       Not effective

•       Used to create a lot of GHG Emissions

•       Ambient Temperature in Winter season can go up to 5 deg. C

SOLUTION OFFERED
 

•       So we offered a Solution of Air Sourced Heat Pump to eradicate all the issue
         they were facing.

•       Heated Water Requirement is: 44 KL/Day @ 80 deg. C

•       Heat Pump Offered: 70kW X 3 Nos

•       The heating of DM water can’t be direct as it was going to be used for
         Hygienic purpose

•        So we heat the DM water using a PHE in between Soft water and DM  water.

To tackle Low ambient Temperature, we used Crankcase Heater

ROI

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