Pharmaceutical companies are striving to balance complex and evolving regulatory demands, operational efficiency challenges, and environmental responsibility in an age of tariffs, cost uncertainty and increasing expectations around sustainable business practices. Sustainability is increasingly becoming a vital consideration for the pharma industry. Traditionally cautious, the sector is now embracing change at a quicker pace driven by the urgency of climate action required to reduce carbon emissions, as well as expectations by consumers and other stakeholders.

Innovative sustainable materials such as bio-based plastics, post-consumer recycled (PCR) content and fiber-based alternatives offer tangible benefits such as reduced carbon footprint, improved recyclability and often cost reductions. The adoption of eco-design principles and established continuous improvement methodologies such as Kaizen, have been demonstrated as central to driving meaningful change – lowering carbon emissions and minimizing negative environmental impact.

Even still, the complexities of implementing sustainable packaging solutions and adopting change in both commercial and clinical settings presents their own distinct challenges.

Why has pharma been slow to use more sustainable packaging?

When it comes to sustainability, pharma has been relatively slow to change, admits Hywel Woolf, Global Sustainability Manager at Sharp, a leading CDMO with more than 70 years of pharma packaging services experience.

“However, over the past 5-10 years there have been big developments and commitments made in sustainability,” says Woolf. “Across big pharma, CDMOs, and CMOs, we’re seeing strong leadership and major commitments to better understand the impact of their operations. Our industry partners, our customers, and ourselves, are doubling down on progressive action on sustainability, leading change and improvement.” 

The regulatory complexity of the pharma sector can be a major hurdle, explains Woolf, because it is much harder to introduce any changes. In highly regulated industries like pharma, every new material or process must be thoroughly tested and approved to ensure it does not compromise the safety or quality of drug product or the drug delivery system. Quality is paramount in our industry, with patient safety bring the absolute priority. However, this can discourage some companies from developing and adopting greener alternatives to their proven, tried and tested materials. As a result, even when suitable sustainable alternatives are available, caution and uncertainty often delays or limits their adoption by pharma companies.

“While some perceive that the switch to more sustainable options is more expensive,” adds Woolf, there are often many ‘easy wins’ before a tipping point is reached. In fact, taking a more sustainable approach to packaging materials will often result in identifying opportunities for cost saving or avoidance by streamlining operations, increasing efficiencies, cutting waste or consuming less energy.

How Sharp is approaching sustainability

Mitch Darnell is a structural designer within Sharp’s design group. He explains that Sharp established a Sustainable Materials Innovation Group (SMIG) as part of its sustainability strategy. SMIG is a dedicated cross-functional group charged with identifying new eco-materials and proactively engaging with Sharp’s supply chain network and clients on sustainability-related projects.

“We engage directly with our vendors and our clients to determine what’s out there. We have new alternatives for paperboard. We have successfully implemented the use of folding box board (FBB) for secondary packaging to reduce waste for many clients.  It is almost identical in terms of strength but it’s 30% lighter than traditional solid bleached sulfate (SBS) paperboard so there are cost saving opportunities when it comes to transportation, as well as time saved when it comes to implementing it into our own supply chain.

“We have also been investigating bio-based alternatives for thermoform trays and rigid blister packaging. There’s bio–PET to replace regular PET and PVC trays. We’ve also partnered with PaperFoam® to offer trays made from a blend of natural materials, a product that is 100% compostable. We’re seeing a lot of demand for mono-materials when it comes to trays and blisters, which supports more efficient recycling at end-of-life. Another huge factor is the overall reduction in volume of these materials. If we can make these materials smaller, more lightweight, but retain the same strength, then that’s another big win.” 

Sharp’s eco-design initiative 

Sharp is also currently implementing an initiative to embed five key eco-design principles into its design capability and operations[i]. This process initiates a review and alignment of existing packaging design practices with industry-accepted sustainability standards, as identified by groups such as the Alliance to Zero[ii]. The adoption of these principles illustrates a practical commitment to integrating sustainable considerations into every stage of packaging development. Our eco-design principles provide our designers with a guide to encourage sustainable design considerations from the earliest design stage.

By engaging cross-functional teams – in particular design, procurement and continuous improvement – Sharp ensures these principles are actively applied in day-to-day decision-making. The aim is to reduce waste, reduce the use of virgin materials, and enhance recyclability, all while maintaining the exacting standards required for pharmaceutical packaging. Woolf explains that this transition is being managed carefully to ensure that both commercial and clinical packaging solutions benefit from the latest sustainable innovations, and clients are offered packaging options that meet both regulatory requirements and may deliver improved sustainable outcomes.

“The good news is there are plenty of options out there,” says Woolf, “and there is an appetite out there for these solutions. As an organization we have a strong commitment to sustainability, and we’re always on the lookout for clients and customers from both a clinical and commercial perspective, who really want to jump on board with us and make that sustainable change.” 

The importance of early engagement with the right partners

Meaningful progress in sustainability is not something that can be accomplished in isolation. Forming strong partnerships, both within an organization and with external stakeholders including clients, suppliers, and industry experts is essential. “Our goals are inherently shared when it comes to sustainability,” says Woolf. “Early engagement, working together in a partnership to deliver sustainable outcomes, is key.”

Darnell also emphasizes collaboration and education as the foundation for driving sustainability in pharmaceutical packaging: “We’re coordinating with clients at the very beginning, on day one… we want to support them as best as we can with options available to make the process as efficient as possible, as sustainable as possible… collaborating with our clients and our vendors, that is the most paramount point.”   

For further information on Sharp solutions, please download the paper below.

[i] Sharp Eco Vision 2050 | Sharp
[ii] https://alliancetozero.com/