How New Chillers Are Turning Down the Heat on Energy Use

Effective temperature control is essential for biotech and biopharmaceutical operations, from laboratories to manufacturing factories. In our Cambridge laboratory building, chillers – specialized refrigeration systems that remove heat from industrial processes – represented one of the largest sources of electricity demand, accounting for approximately 30% of total site electricity consumption.

In 2025, as part of our broader sustainable operations strategy, we replaced four aging chiller units at this facility, helping to address rising energy costs, enhance reliability and advance sustainability goals. Through meticulous planning, the cross-functional team successfully coordinated efforts to remove and replace the chillers during two weekend shifts to minimize downtime impact on laboratory operations. Navigating significant space constraints, old units were removed and new units installed and commissioned while the existing plant remained fully operational. 

“I’ve led the installation of a number of new chillers in buildings over the course of my career, but this was probably the most challenging project and the most rewarding,” said Tom Choyce, Senior Plant Engineer III. “We knew the update would make the plant easier to operate and better for the environment, but first we needed to overcome complex logistical hurdles. Dozens of people came together to realize the vision. As a result, we expect to cut annual electrical usage by roughly 12%, which will deliver cost savings and environmental benefits.”

The new chillers and distribution pumps are now equipped with Variable Frequency Drives, which help improve efficiency by reducing spikes in electrical demand during startup. Instead of simply turning on or off, the chillers can now adjust to the most efficient speed to operate. 

Chiller upgrades are part of an ongoing portfolio of efficiency projects across our Cambridge campus. Since 2019, the engineering team has completed nearly 40 power reduction projects across multiple buildings. 

“The chiller upgrades and other efficiency efforts are great examples of our environmental sustainability strategy in action,” said Kathleen Woodward, Global Head of Sustainability. “This innovative approach not only benefits our business, but reduces the greenhouse gas emissions that contribute to climate change and can harm human health.”