Packaging pharmaceutical and nutraceutical products for resource efficiency and circularity

“Refuse” means not letting waste be generated in the first place. As early as the packaging design phase, we work with you to identify which components can be eliminated. For example, the printed package insert can be made available digitally – provided this is permitted by regulations. The electronic package insert reduces paper consumption while making it easier to access information.

In manufacturing, “Refuse” can be implemented through specific technical improvements. Examples are:

• Stable production run: Precisely adjusted machine parameters ensure a stable production run and prevent unnecessary waste.
• Waste-free punching: By making maximum use of the packaging material, there is no waste.
• Gentle product handling: Feeding systems such as SyPro and LiPro minimize mechanical stress on sensitive parenteral pharmaceutical products. This reduces glass breakage and avoidable waste.

There are several factors that can reduce the use of resources in the field of pharma packaging. Examples are:

• Optimized machine settings: Precisely configured machine parameters prevent start-up waste and ensure consistently high quality during operation.
• Material-efficient format layout: Optimized packaging design reduces the amount of material used per unit. In blister production, an efficient cavity layout in the foil/film web, for example, increases material yield.
• Harmonized format part designs: By standardizing format parts, components can be reused multiple times. This reduces material requirements as well as storage and logistics costs.
• Digital OEE monitoring: Our Pexcite OEE Monitoring system calculates and visualizes overall equipment effectiveness along the packaging line in real time. This allows you to identify and address specific weaknesses – and reduce process losses in the long term. Alongside our digital tool, our service experts also provide support through process analysis and optimization.

“Reuse” means continuing to use existing machines and components for as long and as efficiently as possible. Extending the service life of machinery and equipment helps reduce the need for new primary raw materials.

Our comprehensive service portfolio helps you extend the service life and improve the efficiency of your packaging machines. It ranges from maintenance and calibration to technical and electrical upgrade packages. We can also retrofit existing machines to process mono-materials, bio-based or fibre-based materials and recyclates, for example by adding new formats. This enables material changes to be implemented without the need to invest in new equipment.

Alternatively, we offer fully reconditioned used machines – another way to conserve resources and reduce investment costs.

Recycling is an indispensable component in the further development of sustainable pharmaceutical packaging, if only because of regulatory requirements.

We work with you to evaluate recyclable materials and assess how they can be integrated into packaging processes. The focus is on mono-material solutions, such as mono-blisters made of HDPE, PP, PET and paper, or cardboard trays as an alternative to plastic trays for parenteral products.

Composting may be a viable disposal option for certain types of packaging. Under the conditions found in industrial composting facilities, compostable materials can break down completely, thereby reducing waste.

We will work with you to determine whether compostable materials can be effectively used in your application, and under what regulatory and technical conditions.

Under the EU Packaging Regulation (PPWR), packaging must be systematically adapted to the principles of the circular economy – through mandatory design, material and documentation requirements. The aim of the regulation is to reduce packaging waste, promote reuse and recycling and establish uniform standards for packaging design and labeling across the EU.

For sensitive areas such as pharmaceutical packaging, certain exceptions or transition periods apply. That is why a case-by-case assessment is often necessary.

To the EU Regulation

Modern packaging solutions for the pharmaceutical industry combine uncompromising product protection with improved environmental performance. They reliably protect medicinal products, comply with stringent regulatory requirements and are designed to minimise the use of materials and resources. One way of achieving this is by using mono-materials optimised for recycling.

Suitable materials for packaging in the pharmaceutical and consumer health sectors include plastics such as high-density polyethylene (HDPE), polypropylene (PP) and polyethylene terephthalate (PET), as well as fibre-based materials. Their recyclability depends on the specific packaging structure and the applicable recycling conditions.

There is no one-size-fits-all answer to which solution is appropriate in each individual case; it depends on the specific packaging application. The key factors are the requirements for primary or secondary packaging, as well as aspects such as processing and line integration.

At the Packaging Competence Center, we test and validate suitable material options. Under real-world production conditions, we work with you to determine which solution meets your product-specific requirements and can be reliably integrated into your packaging line.

The environmental performance of pharmaceutical packaging can be systematically evaluated using a Life Cycle Screening, among other methods. This approach analyses potential environmental impacts across the product life cycle to provide a sound basis for decision-making.

A Life Cycle Screening offers, among other benefits:

• Data-driven insights into relevant environmental parameters
• Systematic identification of opportunities for environmental optimisation
• Support in meeting regulatory requirements and corporate environmental objectives

At the Packaging Competence Center, we conduct these assessments and use the results, in collaboration with you, as the basis for selecting and further developing packaging concepts.

There are several alternatives to PVC blisters. The most suitable solution depends on the specific product, the required barrier properties, and the design of the packaging line. Examples of mono-material alternatives designed for recyclability include:

• PP (polypropylene): PP provides reliable protection against moisture, is transparent and offers defined push-through performance in blister packs. As a mono-material foil, it facilitates single-material processing and material recovery.
• HDPE (high-density polyethylene): HDPE provides a high level of moisture protection. HDPE mono-material blisters can be sealed effectively, provide a high-quality appearance and, depending on the packaging structure and recycling route, may be recyclable.
• PET (polyethylene terephthalate): Stands out for its high transparency and good mechanical stability.