SPOT LIGHT

Green electricity has an important role to play in making pharmaceutical manufacturing more sustainable. Translating environmental objectives into practical progress, however, requires renewable energy solutions tailored to each site’s infrastructure, electricity demands and operational requirements

Volker Wolfart at CARBOGEN AMCIS

For manufacturers, purchasing electricity from renewable sources can contribute to this transition. Generating renewable electricity on site provides another opportunity, enabling energy to be produced close to where it will be consumed and used directly within manufacturing operations.

This distinction is important. CARBOGEN AMCIS had already been purchasing certified electricity from renewable hydropower for several years. The Hunzenschwil project therefore represents a further development in its approach, moving from purchasing renewable electricity to generating a proportion of its energy directly on site. This provides greater visibility and control over the source of the electricity used, while reducing reliance on external supply.

This investment also reflects the increasing attention pharma companies are giving to the environmental performance of their supply chains. Manufacturers and service providers are being asked to provide detailed information about their energy use and sustainability performance. Demonstrating practical investment in renewable generation can therefore support both environmental objectives and customers’ expectations of their partners.

However, introducing on-site renewable generation at an established production facility is not necessarily straightforward. Existing buildings, technical infrastructure, available space and patterns of electricity consumption will all influence what can be achieved. The most appropriate solution must therefore be shaped around the conditions and requirements of the individual site.

Turning sustainability objectives into practical action

Company-wide sustainability objectives ultimately need to be translated into tangible measures at individual sites. This requires manufacturers to look beyond broad ambitions and assess where meaningful and achievable progress can be made within their operations.

When considering on-site solar generation, rooftop photovoltaic systems may appear to be the most obvious solution. At an established industrial facility, however, roofs may already accommodate essential technical infrastructure or may not have the structural capacity required for the installation.

This was the challenge facing CARBOGEN AMCIS at its Hunzenschwil site in Switzerland. The roof of the production building was already occupied by large ventilation systems, while the permitted roof load made a neighbouring building unsuitable for photovoltaic panels.

Rather than preventing the project from progressing, these limitations led CARBOGEN AMCIS and its partners to consider an alternative approach. An unused industrial reserve plot provided space for the development of a ground-mounted photovoltaic system.

The experience demonstrates the value of assessing the whole site and remaining open to solutions that may be less conventional within an industrial setting. The most immediately apparent option may not always be viable, but the wider site may present other opportunities to generate renewable energy.

The potential value of an on-site photovoltaic system is not determined by its installed capacity alone. Manufacturers must also consider when the electricity will be generated, how this corresponds with the site’s pattern of consumption and how much of the energy can be used directly within operations.

At Hunzenschwil, the system comprises 2,448 photovoltaic modules and has an installed capacity of 1,200kWp. The panels have been arranged in an east-west orientation with a 15-degree tilt and required some extra anchoring to withstand harsh winds and weather conditions.

According to the project information, this configuration supports more even electricity generation across the day, increases the potential for the electricity to be consumed on site and allows more modules to be accommodated within the available area.

This illustrates an important consideration for industrial energy users. Designing a system around the site’s electricity requirements may be more valuable than focusing solely on maximum generation at a particular point in the day. Aligning generation more closely with operational demand can increase the proportion of renewable electricity used directly by the site.

The electricity generated at Hunzenschwil will be used primarily within CARBOGEN AMCIS’s own operations. The system is expected to meet the site’s daytime electricity demand.

The Hunzenschwil system was developed in collaboration with energy provider IWB and its subsidiary Planeco, which were responsible for the planning and implementation of the project.

Following a three-month construction phase, the facility was officially opened on 25 June 2026. It will increase the amount of locally generated renewable electricity used within the site’s pharma development and manufacturing operations.

By replacing some externally supplied electricity with solar power generated and consumed on site, the installation is expected to contribute to reducing the carbon footprint of the Hunzenschwil operation. The site uses approximately 2GWh annually, with the system expected to provide more than half of this requirement.

Delivering renewable energy infrastructure within an operational industrial environment also requires effective collaboration. Internal understanding of the facility and its requirements must be combined with the technical expertise needed to plan, design and implement an appropriate system.

SR-STUDIOS

The Hunzenschwil project brought together CARBOGEN AMCIS, IWB and Planeco, alongside engagement with relevant local and cantonal stakeholders. This collaborative approach helped translate the objective of increasing renewable energy use into a functioning installation shaped around the realities of the site.

CARBOGEN AMCIS began the selection process by defining its technical and operational requirements and assessing several potential providers. The final decision reflected not only the proposed cost, but also the provider’s willingness to develop a solution around the site’s specific requirements and an established relationship of trust. This reinforced the importance of selecting a partner that would listen to the company’s requirements and work collaboratively to deliver an appropriate solution.

On-site solar generation should not be viewed as a standalone solution to the environmental challenges associated with pharma manufacturing. Its contribution is most meaningful when it forms part of a broader and continuing approach to energy use.

CARBOGEN AMCIS describes the Hunzenschwil installation as another building block within its sustainability strategy. The company aims to improve its energy efficiency continuously and steadily increase the proportion of renewable energy used within its production processes.

This reflects the incremental nature of progress. Improving the sustainability of an established manufacturing operation is unlikely to be achieved through a single project. It requires a series of practical measures that respond to the circumstances of individual facilities while contributing to longer-term environmental objectives.

For pharma manufacturers considering on-site renewable electricity generation, the starting point should be a detailed assessment of the site, its energy requirements and the opportunities presented by its buildings and available land. The design should consider how closely generation can be aligned with operational demand and how much of the electricity can be consumed directly on site. Where the most conventional solution is unavailable, a broader assessment may reveal a viable alternative.

The Hunzenschwil experience also highlights the importance of regular communication, forward planning and appropriate specialist expertise. Weekly discussions with the project team, supported by external architectural and technical expertise, helped to identify upcoming requirements, test assumptions and address potential issues before they affected delivery.

Individual renewable energy investments should ultimately form part of a longer-term approach that combines greater use of green electricity with continuing improvements in energy efficiency. By shaping each solution around the circumstances of the individual facility, manufacturers can turn wider sustainability objectives into practical and sustained progress.