Posted on March 25, 2025

Leakages in a manufacturing facility are more than just a minor inconvenience—they can lead to significant financial losses, environmental concerns, and operational inefficiencies. For industries like pharmaceuticals, where precision and efficiency are paramount, eliminating leakages is not just a goal but a necessity for sustainable operations. Leading pharmaceutical consulting companies emphasize the importance of a well-engineered facility to minimize such risks and ensure long-term efficiency.

The Impact of Leakages on Sustainability

Leakages can drain resources and contribute to environmental pollution, making sustainability efforts difficult. While companies often focus on reducing accidents to zero, achieving zero leakages is equally possible with strong leadership commitment. An effective zero-leakage facility provides multiple benefits, including:
• Material Conservation – Reducing waste and optimizing resource usage.
• Emission Control – Minimizing pollutants released into the environment
• Pollution Reduction – Ensuring cleaner air and water.
• Fire and Explosion Prevention – Mitigating safety hazards linked to gas and steam leaks.
• Increased Productivity – Preventing disruptions and improving overall efficiency.
• Reduced Forced Shutdowns – Avoiding production halts due to system failures.
• Lower Batch and Cycle Time – Enhancing process efficiency.
• Improved Workplace Environment – Eliminating unwanted odors and noise pollution.

The Hidden Costs of Leakages in Pharmaceutical Facilities

In context of Pharmaceutical industries, most leakages are often observed in compressed air, steam, laboratory gases in good maintained facility and these are very costly utility every facility uses. Study suggest that in average a facility encounters about 200 leakages in a year which can be segregated as following.

A common leakage observed in almost all pharma facility is compressed air from valve spindles, pipes, welding, temporary joints, PU tube connection etc. accompanied by irritating hissing noise.

A 2mm hole at 6 bar pressure can cost a facility above Rs200,000/ year. (USD2400/ year). Similarly, a with a 5mm leakage on steam line with 3 bar g operating pressure can emit 23.67 kgs/hr. steam which could cost annually about Rs 850,000 per annum or USD 10365/ annum.
• 1-2% as major and requires force shutdown.
• 2-4% as serious and requires high repair cost
• 5-10% as minor with certain damages
• Other 85% are losses facility management does not effectively monitor and consider those as uncontrollable at times.

Effective Measures to Achieve a Zero-Leakage Facility
Leakages are preventable, and management must take proactive steps to mitigate them. Engaging with engineering consulting services can help develop a structured approach to achieving leak-free operations. Here are some key measures:
1. Zero Leakage as a Policy, Not an Option
Commitment from top management is crucial. Zero leakage should be embedded into corporate policies and operational goals.

2. Design and Installation Considerations
Studies show that 80% of leakage issues stem from poor design, improper component selection, and incorrect installation. Collaborating with epc companies specializing in pharmaceutical manufacturing ensures high-quality materials and precise installation to prevent future losses.

3. Life Cycle Costing Approach
Facilities should evaluate long-term operational costs while selecting equipment rather than opting for cheaper, short-term solutions.

4. Frequent System Audits and Monitoring
Regular inspections and audits help identify hidden leakages. Monitoring tools and automated detection systems can significantly improve leakage management.

5. Translating Losses into Financial Terms
By quantifying leakage-related losses in monetary terms, organizations can drive accountability and encourage continuous improvement.

Conclusion

Leakages are not an inevitable part of facility operations—they are preventable with the right strategy, investment, and commitment. Implementing a zero-leakage policy can save money, enhance sustainability, and improve operational efficiency.

For pharmaceutical and other manufacturing industries, eliminating leakages is a vital step toward achieving environmental responsibility and long-term profitability.

Is your facility prepared to achieve zero leakages? The time to act is now!

How Pharma Access Can Help

At Pharma Access, we specialize in designing and implementing leak-proof, sustainable manufacturing facilities. With our expertise in engineering consulting, EPC (Engineering, Procurement and Construction) projects, and project management consulting services, we provide innovative solutions to optimize your facility’s performance and sustainability.

Our unique approach, ENGICUTION (Engineering + Execution)—a seamless integration of engineering and execution—ensures that every project meets the highest standards of quality, efficiency, and compliance. By combining precise planning with flawless execution, we help clients achieve operational excellence with minimal risk and maximum sustainability.