How Smart Technology is Helping Reach Sustainability Goals in Drug Packaging

At conferences and trade shows up and down the calendar, bio/pharmaceutical companies take the opportunity to showcase new, updated, or redesigned equipment, responding to not only the latest demands of the market, but also the innovations of competitors. In this interview with Pharmaceutical Technology®, Sheikh Akbar Ali, PhD, general manager and head of Development and Technology for ACG Packaging Materials, reviews the state of equipment innovation, the emerging technologies that are shaping a new standard of efficiency, how global pressures are affecting the supply chain for raw materials, and what options are available to manufacturers who desire to make their processes more sustainable.

A leap forward in accuracy

PharmTech: To start, what are some general trends you are seeing in equipment? Smart tools and three-dimensional (3D) printing are two specific areas in which we have observed progress so far in 2025, and artificial intelligence (AI) continues to be a growing factor in all types of processes. What is most in demand at the current time?

Akbar (ACG): One growing trend in pharmaceutical packaging is the move toward digital and laser printing technologies. Digital, or on-demand, printing is gaining popularity for enabling batch-level information to be printed just before medicines are packed. This supports traceability, eliminates errors, and increases patient safety as well as flexibility, especially in smaller or personalized medicine batches. Laser printing is also emerging, offering a high-energy, ink free alternative for durable and tamper-evident markings. ACG has been investing significantly in AI to develop smarter equipment. As an example, our vision inspection systems are capable of detecting even the slightest manufacturing defects, ensuring only flawless products are produced. The integration of AI has resulted in a quantum leap forward in defect-detection accuracy, particularly for low-contrast product and foil combinations. Also, training these systems now requires minimal human involvement, with the machine continuously learning and refining its performance through deep learning, and improving its own efficiencies incrementally.

PharmTech: Many companies are taking steps to increase capacity to meet the demands of their customers. Is there a category of equipment that companies are tending toward including in their expansion plans?

Akbar (ACG): Like many other sectors, pharmaceutical companies are highly attuned to cost efficiency and inventory management. With a growing emphasis on sustainability, they are now equally attentive to the carbon footprint of their products. As a result, packaging companies are focusing not just on capacity building, but on developing capabilities to produce packaging with the lowest possible environmental impact. Particular attention is being given to solvent-free adhesives and sealing lacquers. Coating and laminating lines that accommodate these solvent-free materials are becoming increasingly valuable. Energy efficiency is another major consideration. Technologies that capture waste heat from the process stack and reuse it to reduce overall energy consumption are gaining traction. And the demand for sustainable packaging materials has accelerated the need for advanced blistering lines, and systems that are faster, modular, and reconfigurable with minimal change over time. These innovations enable manufacturers to efficiently handle a variety of eco-friendly materials without compromising on productivity or quality. In addition, companies setting up new production lines or facilities are prioritizing digital and on-demand printing infrastructure. This enables greater operational flexibility and supports compliance with evolving regulatory requirements.

Strengthening sustainability

PharmTech: How have outsourcing relationships and partnerships evolved to meet the manufacturing needs of all concerned—especially given the currently tenuous geopolitical climate?

Akbar (ACG): Global supply chain disruptions—driven by geopolitical tensions—are significantly affecting raw material sourcing and timely delivery of packaging materials to pharma companies. This creates bottlenecks in both production and delivery. The issue is particularly severe for sustainable materials needed to meet net-zero goals, as these materials are either scarce or unaffordable.

PharmTech: What about single-use technology? Where do you foresee the next stage of innovation in that area, and how does that align with sustainability goals for the industry?

Akbar (ACG): In pharmaceutical applications, reusing packaging is not feasible due to contamination risks. Therefore, single use remains the industry standard. However, significant innovation is occurring to align single-use packaging with sustainability goals. Key developments include, firstly, polyvinyl chloride (PVC)- and halogen-free alternatives in thermoforming and cold forming applications, such as thermoform blisters where the PVC is replaced with APET (amorphous polyethylene terephthalate), PP (polypropylene), or PE (polyethylene); cold form blisters where the PVC is replaced with PP, PE, or BOPET (biaxially oriented polyethylene terephthalate), lidding foil where the halogenated primers and heat seal lacquers (HSLs) are replaced with halogen-free alternatives, or universal sealing lacquer instead of specific lacquer for specific sealing layer. A second key development is in the reduction of mass, evidenced by a compact blister where the blister dimension has been reduced to accommodate the increased number of blisters per stroke of the blister line. A third development is in recyclable materials, namely thermoforming material where both the forming and lidding material are made of the same material and can be recycled in existing recycling infrastructure. And the last is in biodegradable and compostable materials—biodegradable PVC, which is certified to degrade faster than the regular PVC, and paper-based blister packs, which are made of certified compostable materials. These developments enhance recyclability, minimize material usage, and offer safer disposal options, bringing sustainability to single-use packaging without compromising either safety or functionality.

What’s on the horizon

PharmTech: Are there any new, imminent, or expected regulatory changes that companies and their clients should be aware of?

Akbar (ACG): There is a notable gap in global regulations for alternative sustainable packaging materials. Current standards primarily cover traditional materials like PVC, which hampers the adoption of newer, eco-friendly options. This regulatory vacuum makes it difficult for pharmaceutical companies to switch to sustainable formats, despite technological readiness. Additionally, the European Union (EU)’s Carbon Border Adjustment Mechanism is a pressing concern. It imposes a tax on imported products, increasing the cost of non-EU packaging materials. This may impact pricing and competitiveness for companies like ACG that export into the EU market.

About the author

Patrick Lavery is an Editor for Pharmaceutical Technology®.

Article details

Pharmaceutical Technology®
Vol. 49, No. 5
June 2025
Pages: 20–21

Citation

When referring to this article, please cite it as Lavery, P. How Smart Technology is Helping Reach Sustainability Goals in Drug Packaging. Pharmaceutical Technology 2025 49 (5).