Profiles in Energy Efficiency
ENERGY STAR
Boiler Upgrades Save Money & Energy: Allergan - Westport
Allergan is a global, integrated pharmaceutical company that discovers, develops, manufactures and
markets prescription medicines. Headquartered in Irvine, California, the company has more than 9,000
employees worldwide and operates ten major manufacturing and R&D facilities worldwide with five of those
located in the United States. AI lergan's Westport Ireland site is a 450,000 square foot pharmaceutical
manufacturing facility which was established in 1977.
An active partner in the U.S. EPA's ENERGY STAR program, Allergan has earned ENERGY STAR
certification for superior energy efficiency for its Waco, Texas manufacturing site and three of its U.S.
headquarters buildings. The company also leverages ENERGY STAR tool & resources to help them
achieve their goal of a 15% reduction of greenhouse gases by 2015. Allergan more than reached its prior
five year goal of a 5% reduction in greenhouse gases by reducing these emissions by 15% in 2010.
Allergan's Westport facility employs three steam boilers capable of producing 5,455Kg of steam per hour
for use in manufacturing processes and space heating. These boilers where originally designed to use fuel
oil and consumed the equivalent of 29,500,000 Kwh (net calorific value) annually. With the expansion of
the natural gas infrastructure in Ireland and rising cost of fuel oil, Allergan decided to convert the boilers to
run on natural gas, with fuel oil used only a backup. In addition, Allergan added a boiler flue gas
economizer on the primary boiler and retrofitted 135 steam traps with more energy efficient GEM traps
which also offer a lower failure rate.
As result of converting to natural gas and improving the efficiency of the boiler and steam system, Allergan
was able to achieve significant cost and environmental benefits.
Savings:
•/ Lower fuel costs by 40% or $1 million annually.
S Reduced annual C02 emissions by 30% or 2035 metric tons.
S Reduced NOx emissions.
Additional Benefits:
S The C02 reduction at the site supports the corporate goal of a 15% reduction in greenhouse
emissions and distinguishes Westport among Allergan sites worldwide.
S The estimated payback of this project is 0.5 years and meets Allergan's requirements for
strategic climate and energy projects.
S Converting to natural gas has also allowed planning for a cogeneration facility to proceed.
S Continuously improving energy efficiency keeps the facility competitive.

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