Manoj V
Senior HVAC Technical Director & Biotech Manufacturing Expert

About Me

Manoj V

Senior HVAC Technical Director| Pharmaceutical & Biotech Manufacturing Expert

With over 25 years of HVAC experience in sterile pharmaceutical environments—10 years with AstraZeneca in London and 15 years with Strides Pharma in Bangalore and ABB—I specialize in maintaining HVAC systems for GMP-compliant cleanrooms (Grades A–D). I ensure air quality, temperature, and pressure controls that meet global regulatory standards including EU-GMP and ISO 14644-1.

Key Skills

HVAC Preventive & Corrective Maintenance

  • Cleanroom HVAC (Grade A–D) & Environmental Monitoring

  • AHUs, Chillers, Compressors, Dehumidifiers

  • HEPA Filter Integrity & Air Balancing

  • BMS & SCADA-based HVAC Controls

  • cGMP, ISO 14644-1, EU-GMP Compliance

  • HVAC Qualification: URS, IQ, OQ, PQ

  • Root Cause Analysis (RCA) & CAPA Implementation

  • Technical Drawings, SOPs, and Audit Documentation

  • Calibration Records & Compliance Logs

AstraZeneca Case Study

HVAC Optimization and Environmental Control at AstraZeneca’s Sterile Pharma Facility (London)

Project Overview:

During my 10-year tenure at AstraZeneca, I played a critical role in the maintenance, validation, and enhancement of HVAC systems across sterile manufacturing zones.

Key Contributions:

1. HVAC Validation & Integration

  • Performed post-maintenance HVAC validation for cleanrooms (Grade A–D)

  • Developed HEPA filter test protocols that reduced vendor dependency and cut costs by 20%

  • Integrated legacy HVAC infrastructure into a modern BMS for real-time monitoring

2. Digital Monitoring & Compliance

  • Automated SCADA systems for 21 CFR Part 11 compliance

  • Led cross-functional collaboration to enable remote environmental alerts

  • Helped digitize HVAC logs for audit readiness and smoother MHRA inspections

3. Training & Audit Readiness

  • Trained new recruits on cGMP-compliant HVAC troubleshooting

  • Played a vital role in preparing the facility for global audits including FDA and EU-GMP inspections

4. Cleanroom Performance Stability

  • Designed air balancing strategies for pressure cascade management

  • Conducted root cause analyses on air flow issues in aseptic zones

  • Supported optimization of air change rates to improve energy use without compromising quality


Impact Summary:

  • 20% Reduction in filter validation costs

  • 100% Audit success rate over 10 years

  • 24/7 Environmental Monitoring Integration

  • Zero downtime from HVAC-related incidents during production

Visual Suggestions:

  • Flow diagram showing integration of legacy HVAC with BMS

  • Charts showing energy efficiency gains

  • Image carousel: cleanroom AHUs, control panels, filter testing

AstraZeneca Facility HVAC Modernization

Location: London, UK
Lead Engineer: Manoj V, HVAC Technical Director
Project Scope: Climate-Optimized HVAC System Upgrade for Pharmaceutical Distribution Centre

Project Overview:

With over 100 staff working during the day and 40 on the night shift, the site handles 70,000–135,000 single-item orders daily and stores up to 16,000 product lines. Due to the critical nature of pharmaceutical logistics and packaging standards, AstraZeneca required a major HVAC system upgrade to meet global compliance standards while optimizing temperature, energy usage, and air purity.

Project Objectives:

The client needed:

  • Indoor temperature never to exceed 25°C

  • Strict control of humidity levels to protect packaging materials

  • Positive pressure to reduce dust ingress

  • Filtered, fresh air supply to maintain GMP conditions

  • A system with low energy consumption and low cost of ownership

Solution by Manoj V

With over two decades of HVAC experience in pharmaceutical environments, Manoj V led the engineering assessment and implementation of an indirect evaporative cooling system using energy-efficient, non-humidifying air handling units (AHUs).

Each of the facility’s four zones was fitted with five modular cooling units, each controlled independently. The system delivered:

  • 100% fresh filtered air to maintain pressurization

  • Air cooling without adding moisture—essential for packaging integrity

  • Lower energy usage due to the absence of refrigerant-based compression

  • Reduced water consumption—units flush water for just 1 out of every 8 minutes

  • Digital SCADA integration for real-time monitoring


✅ Project Results

  • Temperature Control: Achieved a consistent indoor temperature of 22°C, outperforming the 25°C requirement

  • Dust Reduction: Positive pressure and strip curtains reduced external dust infiltration, protecting robotic picking systems

  • Energy Efficiency: The system’s energy usage remained stable regardless of outside temperature

  • Water Conservation: System used significantly less water than traditional evaporative cooling setups

  • Low Maintenance: Few moving parts, no compressors, and reduced service needs led to long-term cost savings

Consultancy Services

  • Engineered HVAC solution design and vendor selection

  • Oversaw commissioning and validation for GMP zones (Grade A–D)

  • Integrated BMS/SCADA controls for FDA 21 CFR Part 11 compliance

  • Conducted SOP updates and staff training for long-term sustainability

  • Created digital logbooks for audit-readiness and maintenance tracking

HVAC Retrofit for AstraZeneca – Enhancing VFD Efficiency & Sustainability

Location: UK-based Pharmaceutical Facility
Lead Engineer: Manoj Veetil, HVAC Technical Director
Project Scope: VFD System Upgrade & Retrofit for HVAC Infrastructure

Project Overview:

As part of AstraZeneca’s commitment to sustainable, efficient pharmaceutical operations, the company sought to modernize its HVAC system at one of its key UK distribution and production facilities. The focus was on retrofitting outdated Variable Frequency Drives (VFDs) and integrating new low-harmonic components to meet current environmental and efficiency standards.

The Challenge

The site was running on obsolete VFDs, with 30 units needing immediate replacement and seamless integration into the existing control network. The objectives were: Achieve <7% total harmonic distortion (THD) at the point of common coupling Ensure zero disruption to pharmaceutical-grade air handling processes during installation Maintain full HVAC system capacity across both drive and bypass modes

Solution by Manoj Veetil

Following detailed consultation with the client’s engineering consultants, Manoj Veetil led the full retrofit strategy. He programmed Low Harmonic VFDs with Modbus communication protocols that interfaced with the Retrofit Bypass Control Unit (RBCU).

The new system delivered:

  • <3% current distortion, exceeding industry requirements

  • Digital input/output mapping with full safety protections

  • Seamless switching between bypass and drive modes

  • Components fully compliant with UL and NEC standards

  • Adherence to a certified startup sequence for optimal performance

Results & Impact

  • No downtime during implementation

  • 3% harmonic distortion—well below the 7% threshold

  • All components UL-listed, fully aligned with regulatory standards

  • “As-Built” documentation provided post-installation

  • Long-term client satisfaction—30 additional units budgeted for 2024