Today, healthcare providers and manufacturers are faced with the complex task of balancing environmental responsibility with the need to maintain the highest standards of product performance, patient safety, and regulatory compliance. The healthcare sector contributes to approximately 5% of global greenhouse gas emissions, with around half of that coming from supply chains. To make a meaningful impact, healthcare supply chains must become more circular and efficient. However, achieving this requires large-scale, collective action.

Reducing emissions

Companies track their emissions across three categories: Scope 1 includes direct emissions from activities the company controls, Scope 2 covers indirect emissions from purchased energy, and Scope 3 represents all other indirect emissions from the value chain before or after the company’s own operations.

Scope 3 emissions are often the largest contributor to a company’s carbon footprint, yet they are also the most challenging to manage. About 75% of emissions across the pharmaceutical companies’ value chain are Scope 3 (McKinsey: Accelerating the transition to the net zero in life sciences, 2023).

Given that Scope 3 emissions often make up the largest portion of a company’s carbon footprint and are the most difficult to manage, how can the pharmaceutical industry address these emissions in packaging design while balancing sustainability with regulatory compliance and patient safety?

Challenges and considerations

While the pharmaceutical industry has set ambitious targets to reduce emissions, the challenge is compounded by the special requirements of pharmaceutical packaging. Packaging must protect the product from contamination and environmental factors, comply with strict regulations, and ensure safety (e.g., extractables and leachable in plastic packaging). 

Additionally, packaging communicates vital information like dosage and ingredients and, in some cases, functions as a drug delivery system (e.g., injection pens, inhalers). Other features like child resistance, tamper evidence, and elderly-friendly design may also be required.

When selecting materials for packaging, factors like storage conditions, temperature extremes, and sterilization processes must be considered. The lengthy validation process requires careful change management to avoid any unintended alterations.

Advancing sustainability in pharma packaging

The healthcare sector is developing and implementing innovative solutions to advance the sustainability of pharmaceutical packaging and there is a growing focus on evaluating the carbon footprint of packaging materials and considering end-of-life scenarios like recyclability. 

UPM Raflatac had the opportunity to discuss this topic during its recent joint webinar with Corning Life Sciences. Corning has introduced the Viridian Vials, a sustainable solution designed to reduce glass waste and Scope 3 emissions in pharmaceutical packaging while maintaining the required performance standards. 

The vials are made from type 1 Borosilicate glass with a thinner wall, reducing material use by 20%. Additionally, an external coating is applied to improve vial handling, reduce damage, and enhance filling line efficiency. The Viridian Vials offer up to a 30% reduction in Scope 3 emissions cradle to gate.

Pharmaceutical labeling may seem like a small component of packaging, but it plays a crucial role in ensuring the accurate communication of vital information such as dosage and usage instructions.

The label must remain securely in place to prevent any loss of critical data, which can be particularly challenging with small-diameter containers. Furthermore, it is essential that the label remains legible throughout the product’s lifecycle to prevent any risk of misinterpretation. This requires materials that allow for sharp, clear printing.

In addition, pharmaceutical labels must withstand extreme conditions, including exposure to very low temperatures — sometimes as low as -80°C — during transportation and storage. To address these challenges, thorough testing and selection of the appropriate materials are vital. Above all, the safety of the patient remains the primary concern, serving as the foundation for all packaging decisions in the pharmaceutical industry.

Companies have already made significant progress in improving secondary packaging, such as through elimination or lightweighting. However, the next challenge lies in primary packaging, where the focus must shift to integrating sustainable practices without compromising safety.

PPWR on the horizon

Packaging waste in the EU has risen by more than 20% over the past decade, and without proactive actions, it is projected to grow by an additional 19% by 2030. Specifically, plastic packaging waste is expected to increase by 46%. PPWR (Packaging and Packaging Waste Regulation) requires companies to align with stricter recycling targets, reduce excess packaging, and ensure packaging materials are recyclable or reusable. This legislation also applies to pharmaceutical packaging to some extent.

This article originally appeared on the UPM Raflatac website.