It's hard to find any chemical or pharmaceutical company that does not deal with process optimization, increased productivity, climate protection or cost reduction. Currently sustainable, ecological and economical business is required to compete in the global market.

The current financial crisis has compelled many businesses to react to the actual challenges. Companies have to find answers to the following questions:

• How to react to the economic slowdown?
• How to best utilize production capacities when demand is diminishing?
• How to adjust financial objectives and initiate cost saving measures?
• How to think about environmental stewardship?

The correct answer to the economic change is difficult enough for all market players, but especially so for companies in the chemical and pharmaceutical industry, who have to respond not only with programs for process optimization, increased productivity and cost reduction, maybe even a change in their business model, but also at best with green initiatives and a corporate commitment to sustainability. Various studies from industry analysts at Goldman Sachs or A.T.Kearney reveal that companies with a "... true commitment to sustainability appear to outperform their industry peers ..."

Innovations for a Sustainable Environment

For those companies for which sustainability is not just a byword to improve the company's reputation, the investment in sustainability is employed to generate profitable business. Green technologies can create a healthy margin and sustainable business improves the competitive advantage.  In the chemical and pharmaceutical industry environmental stewardship leads to sustainable business as can be seen by initiatives like "Responsible Care" and "Greening of Industry".  Based upon these conditions, Siemens -offers a portfolio that not only meets but exceeds the current challenges of the industry. It is based completely on sustainability and highlighted solutions for the topics of energy efficiency, emission control, waste prevention and water processing. Furthermore, Siemens offered answers to how modern technologies and innovative solutions contribute to long-term sustainability. The answers are plant and process optimization, better use of resources and protection of the environment.

Energy And Emission

Better protection of the environment does not necessarily mean an inherently high -investment cost. Taking into account the entire life-cycle costs, the majority of the investments in energy efficiency produce a fast return on investment. For example more than 97% of the life-cycle costs of a motor are allocated to its energy costs, only 3% to the purchase and installation costs. In continuous operation Siemens energy-saving motors amortize in general within three years of initial operation. A similar cost-benefit calculation can be made for variable frequency drive converters. They reduce the electrical consumption of pumps and fans by up to 60 %. Not only do they improve efficiencies but they also reduce energy consumption, therefore providing a double cost saving strategy.

Siemens process instrumentation and analytics assist operators in being able to run processes closer to they're specified limits, ensuring higher efficiency and lower energy consumption. This can be performed by -utilizing instrumentation such as the Sitrans SL, an in-situ diode laser based spectrometer, which monitors the oxygen concentration directly in the combustion zone of a boiler to save energy and reduce pollution. Monitoring the exhaust gases in solvent combustion processes or flares by process analytic equipment (Oxymat, Fidamat or Maxum/Microsam), helps to comply with environmental legislation for continuous emission monitoring systems (CEMS). 
By utilizing condition monitoring, failures are detected even before they can have a negative impact on the process. Sipart PS 2 valve positioned detects deviations in the valve operation; the acoustic diagnostic system DA 400 monitors pumps for preventive maintenance. And even the Siemens devices themselves contribute to reduced energy consumption: The ultrasonic level controller Sitrans LUC 500 with its energy-saving algorithms, the micro-machined gas chromatograph Microsam with a reduction of 80% in gas and power consumption when compared to conventional chromatographs.

Waste And Water

Today, the pharmaceutical industry wastes incredible amounts of valuable resources and money due to processes that create off-spec or low-yield products. Consequently, pharmaceutical companies are implementing waste reduction programs, not only for environmental reasons but also to reduce costs. The key element in the reduction of waste is Process Analytical Technology (PAT). Sipat, the Siemens software solution, supports the application of PAT. With Sipat Siemens offers a way to obtain right-first-time manufacturing, manufacturing performance improvement and development excellence all based on improved process knowledge and understanding.

Conserving water and energy are critical aspects of water system design for the pharmaceutical industry. Water costs, scarcity and strict regulations force companies to explore new solutions to remain competitive. Siemens Water Technologies has pioneered many innovative technologies and processes to optimize water use and reuse. The Siemens solution eliminates the need to re-circulate water. The Siemens S3 process utilizes a sanitize/start/stop approach rather than the potentially wasteful approach of continuously re-circulating water systems. The S3 system runs when needed and stops when not needed, saving water, electrical consumption and wastewater production.

Process Optimization and Key Technologies

At first glance, a distributed control system (DCS) does not seem to be the solution when thinking of sustainability. On closer examination our automation systems for Biogas plants help to produce green energy with exhaust air combustion and waste incineration (co-generation). Simatic PCS 7 covers measures for efficiency increases with energy, water and steam supply, with systems for control and optimization of the raw material usage and quality. The new version of the Simatic PCS 7 process control system with its advanced process library, trend control and alarm control functions helps to shorten engineering, installation and commissioning times, while reducing operation and maintenance costs. Thanks to the new faceplates and color scheme a higher degree of data transparency and responsiveness can be achieved.

With the acquisition of Comos Industry Solutions, formerly Innotec, Siemens is expanding its portfolio and software solutions, supporting economic engineering over the entire life-cycle of process plant and fixed equipment assets. The software package for the basic and detailed engineering is an optimal complement of the existing Siemens software solution and is substantially reducing time and cost for planning, commissioning and operation of the plant or equipment. Also the integrated, object-oriented life-cycle asset management system from Comos contributes to sustainability. It is designed to increase productivity and at the same time to lower production costs and the risks involved.

Sustainable And Global Partnership

At present, the economic crisis and the growing issues of resource constraints and climate change are determining the world economy. Consequently the chemical and pharmaceutical industries have to cut operating costs, optimize business processes and increase resource utilization. With collaborative partners that stress both ecologic and economic business, this and the next generation's future looks bright, even if the global recession puts pressure on sustainable manufacturing and green initiatives. Siemens can help to achieve sustainable business with a variety of products and solutions for plant and process optimization.