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Waters + BD Biosciences & Diagnostic Solutions
BD’s Hunt Valley Campus is a high-performance life sciences manufacturing and R&D facility requiring precision environmental control across labs, clean rooms, and production spaces. With complex HVAC infrastructure—hundreds of VAV systems, multiple air handling units, and a large compressed air system—the facilities team faced mounting pressure to optimize energy performance while maintaining the exacting reliability standards demanded by pharmaceutical and diagnostics manufacturing operations. FacilityConneX was selected following a competitive bake-off trial, ultimately earning Global IT approval and full campus deployment across their 250 Schilling building.
Challenge
Life sciences manufacturing demands precise environmental controls, complex mechanical systems, and strict regulatory compliance—all operating in concert. Waters + BD Biosciences & Diagnostic Solutions faced key challenges:
- Limited Real-Time Visibility: Managing 1,587+ data points across aging VAV systems, air handling units, and compressed air infrastructure with limited visibility into root causes of energy waste and equipment degradation.
- Clean Room Complexity: Clean room manufacturing areas require planned shutdowns for equipment access, making proactive fault identification and pre-planned maintenance essential to avoiding costly disruptions.
- Energy Waste and Equipment Faults: Simultaneous heating and cooling, leaking reheat valves, static pressure deficiencies, and compressed air leaks were driving significant energy waste and unplanned maintenance costs across the facility.
- Sustainability and Utility Goals: Meeting BGE Smart Building Program requirements and corporate energy efficiency targets while ensuring the facility’s performance standards remained uncompromised.
Solution
The BD facilities team at the Hunt Valley Campus partnered with FacilityConneX to deploy the FCX VOICE IoT/AI platform—starting with a competitive bake-off trial and earning full Global IT approval following proven results. Leveraging FacilityConneX’s deep expertise in building analytics, OT/IT integration, and energy optimization, the team established a continuous monitoring and fault detection program across the 250 Schilling building. Key aspects of the solution included:
- Full-Campus IoT Deployment: FacilityConneX deployed FCX VOICE across the 250 Schilling building, mapping 1,587 data points and deploying 1,615 analytics. The deployment began with a competitive bake-off trial and expanded to full campus coverage following Global IT approval, with the building enrolled in the BGE Smart Building Program after an ASHRAE Level 2 audit.
- Continuous FDD Monitoring: Over 35 million fault detection and diagnostics (FDD) checks continuously monitor all systems, surfacing prioritized findings for the facilities team through the monthly FCXperience review process—enabling faster time-to-resolution and reducing wear on critical equipment.
- Targeted Fault Resolution: FCX identified and resolved VAV reheating faults, leaking reheat valves, static pressure deficiencies, mixed air setpoint programming errors, and compressed air leaks—each verified with pre/post trend data. Clean room VAV faults are pre-planned for scheduled shutdown access, enabling the maintenance team to act decisively when access windows open.
- Patented Chilled Water Optimization: FCX’s patented machine learning algorithm optimized the chilled water plant with a dynamic condenser water reset strategy, delivering 132,161 kWh in annualized realized savings. A second phase targeting chiller staging strategy is underway for additional energy and reliability gains.
How FacilityConneX Helped
FacilityConneX empowered Kaye to:
- Reduce On-Premises Footprint: Customers now require far less hardware and software locally.
- Enable Mobility & Transparency: Real-time data access via mobile devices with alarm notifications by email, SMS, and voice.
- Enhance Compliance: Reporting and alerts designed to meet FDA’s 21 CFR Part 11 requirements.
- Predict Equipment Issues: Advanced analytics deliver early insight into potential sensor failures.
- Strengthen Market Position: Kaye gained a competitive edge with a fully modernized SaaS offering that met customer needs faster and more effectively.
Summary
Organization: Kaye Instruments (Amphenol)
Platform Implemented: LabWatch IoT (Powered by FacilityConneX)
Duration: Under 6 months to launch
Key Benefits: Cloud-based scalability, rapid time-to-market, reduced hardware/software footprint, mobile-enabled monitoring, FDA compliance-ready reporting with Intergrated Electronic Signatures.
Results at a Glance
- Millions of automated equipment checks performed daily — keeping the facilities team ahead of failures before they happen.
- Over 321,000 kWh in verified energy savings delivered within the first 8 months.
- 400,000+ kWh in energy waste identified and addressed across facility systems.
- $15,000 in utility incentives secured through the BGE Smart Building Program, with additional savings-based incentives underway.
- Significant daily energy reductions achieved through proactive identification and repair of compressed air system leaks.
- Critical manufacturing maintenance planned ahead of time — reducing unplanned downtime and protecting clean room operations.
- Proven results drove expansion from a single-building trial to full campus deployment, earning company-wide Global IT approval.
Waters + BD Biosciences & Diagnostic Solutions
BD’s Hunt Valley Campus is a high-performance life sciences manufacturing and R&D facility requiring precision environmental control across labs, clean rooms, and production spaces. With complex HVAC infrastructure—hundreds of VAV systems, multiple air handling units, and a large compressed air system—the facilities team faced mounting pressure to optimize energy performance while maintaining the exacting reliability standards demanded by pharmaceutical and diagnostics manufacturing operations. FacilityConneX was selected following a competitive bake-off trial, ultimately earning Global IT approval and full campus deployment across their 250 Schilling building.
Challenge
Life sciences manufacturing demands precise environmental controls, complex mechanical systems, and strict regulatory compliance—all operating in concert. Waters + BD Biosciences & Diagnostic Solutions faced key challenges:
- Limited Real-Time Visibility: Managing 1,587+ data points across aging VAV systems, air handling units, and compressed air infrastructure with limited visibility into root causes of energy waste and equipment degradation.
- Clean Room Complexity: Clean room manufacturing areas require planned shutdowns for equipment access, making proactive fault identification and pre-planned maintenance essential to avoiding costly disruptions.
- Energy Waste and Equipment Faults: Simultaneous heating and cooling, leaking reheat valves, static pressure deficiencies, and compressed air leaks were driving significant energy waste and unplanned maintenance costs across the facility.
- Sustainability and Utility Goals: Meeting BGE Smart Building Program requirements and corporate energy efficiency targets while ensuring the facility’s performance standards remained uncompromised.
Solution
The BD facilities team at the Hunt Valley Campus partnered with FacilityConneX to deploy the FCX VOICE IoT/AI platform—starting with a competitive bake-off trial and earning full Global IT approval following proven results. Leveraging FacilityConneX’s deep expertise in building analytics, OT/IT integration, and energy optimization, the team established a continuous monitoring and fault detection program across the 250 Schilling building. Key aspects of the solution included:
- Full-Campus IoT Deployment: FacilityConneX deployed FCX VOICE across the 250 Schilling building, mapping 1,587 data points and deploying 1,615 analytics. The deployment began with a competitive bake-off trial and expanded to full campus coverage following Global IT approval, with the building enrolled in the BGE Smart Building Program after an ASHRAE Level 2 audit.
- Continuous FDD Monitoring: Over 35 million fault detection and diagnostics (FDD) checks continuously monitor all systems, surfacing prioritized findings for the facilities team through the monthly FCXperience review process—enabling faster time-to-resolution and reducing wear on critical equipment.
- Targeted Fault Resolution: FCX identified and resolved VAV reheating faults, leaking reheat valves, static pressure deficiencies, mixed air setpoint programming errors, and compressed air leaks—each verified with pre/post trend data. Clean room VAV faults are pre-planned for scheduled shutdown access, enabling the maintenance team to act decisively when access windows open.
- Patented Chilled Water Optimization: FCX’s patented machine learning algorithm optimized the chilled water plant with a dynamic condenser water reset strategy, delivering 132,161 kWh in annualized realized savings. A second phase targeting chiller staging strategy is underway for additional energy and reliability gains.
How FacilityConneX Helped
FacilityConneX empowered Kaye to:
- Reduce On-Premises Footprint: Customers now require far less hardware and software locally.
- Enable Mobility & Transparency: Real-time data access via mobile devices with alarm notifications by email, SMS, and voice.
- Enhance Compliance: Reporting and alerts designed to meet FDA’s 21 CFR Part 11 requirements.
- Predict Equipment Issues: Advanced analytics deliver early insight into potential sensor failures.
- Strengthen Market Position: Kaye gained a competitive edge with a fully modernized SaaS offering that met customer needs faster and more effectively.
Summary
Organization: Kaye Instruments (Amphenol)
Platform Implemented: LabWatch IoT (Powered by FacilityConneX)
Duration: Under 6 months to launch
Key Benefits: Cloud-based scalability, rapid time-to-market, reduced hardware/software footprint, mobile-enabled monitoring, FDA compliance-ready reporting with Intergrated Electronic Signatures.
Results at a Glance
- Millions of automated equipment checks performed daily — keeping the facilities team ahead of failures before they happen.
- Over 321,000 kWh in verified energy savings delivered within the first 8 months.
- 400,000+ kWh in energy waste identified and addressed across facility systems.
- $15,000 in utility incentives secured through the BGE Smart Building Program, with additional savings-based incentives underway.
- Significant daily energy reductions achieved through proactive identification and repair of compressed air system leaks.
- Critical manufacturing maintenance planned ahead of time — reducing unplanned downtime and protecting clean room operations.
- Proven results drove expansion from a single-building trial to full campus deployment, earning company-wide Global IT approval.
FacilityConneX can help you identify, prioritize, and solve problems before they become risks. Want help choosing the right system, or need a second opinion on your current setup? We’re just a message away. Contact FacilityConneX at info@facilityconnex.com to learn how secure cloud-based solutions can provide complete data visibility without operational disruption.
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