Integrating Sustainability into the Core of Pharmaceutical Science

Early efforts in sustainability have moved from a "nice-to-have" benefit to a foundational endeavor across the pharmaceutical landscape (1). Understanding and implementing sustainable practices is no longer peripheral; it is a strategic focus dictated by evolving client expectations, rigorous environmental audits, and respecting planetary boundaries (1, 2). This industry shift is a response to global climate pressures—the healthcare sector contributes 4.4% of global carbon emissions—and a recognition that profitability and responsibility must converge (3,4).

The complexity of environmental impact can be seen in the pharma supply chain; up to 75% of a typical pharmaceutical company's greenhouse gas (GHG) emissions originates from scope 3 (2). According to the US Environmental Protection Agency, “Scope 3 emissions are the result of activities from assets not owned or controlled by the reporting organization, but that the organization indirectly affects in its value chain. An organization’s value chain consists of both its upstream and downstream activities. Scope 3 emissions include all sources not within an organization’s scope 1 and 2 boundary. The scope 3 emissions for one organization are the scope 1 and 2 emissions of another organization. Scope 3 emissions, also referred to as value chain emissions, often represent the majority of an organization’s total GHG emissions” (5).

Because scope 3 covers the entire value chain, pharma scientists should integrate sustainability into R&D, manufacturing, and sourcing strategies (6,7).

How does green chemistry optimize API manufacturing?

The manufacturing of APIs is a significant producer of emissions from pharmaceutical companies (8). The largest contributors to the carbon footprint in these operations are the use of solvents, reagents, and precious metal catalysts (6). Applying the principles of green chemistry early in process development is one strategy to reduce emissions (6), because it allows for the implementation of eco-friendly processes and may foster acceptance by regulatory authorities (6).

Recycling solvents and catalysts offers measurable resource savings and carbon footprint reduction by minimizing incineration waste and the need for new raw material production (6). For instance, specialized companies perform the external transformation of used catalysts back into active species. Innovative technologies are emerging to support this, such as Evonik's process for concentrating precious metal-containing organic waste streams using membrane cross filtration (6), and the development of the "Chemistry in Water" platform, which reduces the consumption of organic solvents. Minimizing or eliminating solvent use may be the best sustainability approach (6).

How is sustainability by design used in bioprocess development?

Similar to quality by design, the concept of sustainability by design is taking root (7). This approach requires integrating sustainable practices from the beginning of the development process, because 80% of a drug’s final environmental impact is determined during the early design stages (7).

Key elements of sustainability by design are resource and energy efficiency, waste minimization, and the use of less-hazardous chemicals (7). Driving efficiency may be achieved with higher titer in smaller volumes through process intensification, which lowers the cost of goods while simultaneously reducing emissions (7). Examples of intensification include using high-density cell banking to skip lengthy seed expansions and implementing single-use bioreactors with high turndown ratios (7). Reducing utility usage by specifying a lower quality of purified water (e.g., reverse osmosis quality water) for media makeup and general early-stage buffers can create impactful improvements in resource management (7).

How do innovations in packaging and supply chain collaboration contribute?

Packaging is a significant contributor to scope 3 emissions, but optimizing packaging solutions offers a way to reduce a company’s GHG (2). Fiber-based packaging, derived from sustainably sourced wood and featuring a high recyclability rate (86.6% in the European Union in 2023), is gaining prominence as an option (2). Efforts to reduce packaging’s carbon footprint involve utilizing fossil-free energy in production and maximizing material efficiency through light weighting (2).

For single-use applications, which remain standard due to contamination risks, innovation focuses on alternatives to traditional materials (9). These include adopting PVC- and halogen-free alternatives (such as APET, PP, or PE) in blistering applications and developing recyclable materials for which the forming and lidding components are made of the same substance (9).

The pharmaceutical supply chain is wide and complex and includes a variety of suppliers, such as material producers, contract manufacturers, and packaging and distribution players. Effective sustainability requires collaboration across this entire supply chain (2,7). Because up to 92% of bioprocess emissions come from upstream activities, companies must engage suppliers early and prioritize partners committed to environmentally friendly practices, responsible sourcing, and strong environmental, social, and governance policies (4,7).

What role does smart technology play?

Digital technologies are essential enablers of sustainability goals (9). Smart tools like digital and laser printing technologies support traceability and increase flexibility for smaller or personalized batches (9). Energy-efficient manufacturing equipment is gaining traction, particularly technologies that capture and reuse waste heat (9).

Digital advancements, including real-time monitoring and advanced analytics, facilitate the complex assessment of environmental impacts (7,10). The integration of artificial intelligence (AI) and machine learning (ML) is proving indispensable for overcoming the challenge of insufficient or complex data needed for sustainability assessments (7). ML models can efficiently fill data gaps and provide higher accuracy predictions. Sustainability implications, therefore, may be assessed alongside technical and cost considerations (7).

The goal of sustainability is a commitment to transformative change (3). By embedding these practices into process design, sourcing strategies, and supply chain partnerships, pharmaceutical manufacturers are solidifying environmental responsibility as a strategic competitive advantage, ensuring the delivery of high-quality products in a socially responsible manner (1,7).

References

1. Cole, C. and Miller, D. Sustainability Becomes Essential: Green Manufacturing and Supply Chain Resilience in Bio/Pharma. PharmTech.com, Aug. 15, 2025. https://www.pharmtech.com/view/sustainability-becomes-essential-green-manufacturing-and-supply-chain-resilience-in-bio-pharma
2. Haigney, S. CPHI Frankfurt 2025: Fiber-Based Packaging for Sustainability. PharmTech.com, Oct. 27, 2025.
3. Thomas, F. Strategic Decarbonization. Pharm. Technol. Eur.2024, 36 (8), 6.
4. Haigney, S. Working Together to Improve the Environment. Pharm. Technol. Bio/Pharma Outsourcing Innovation eBook, February 2025, 12–20.
5. EPA. Scope 3 Inventory Guidance. https://www.epa.gov/climateleadership/scope-3-inventory-guidance (accessed Oct. 28, 2025).
6. Challener, C. A. Improving the Sustainability of API Manufacturing with Recycling Technologies. Pharm. Technol. 2024, 48 (10), 18–20, 33.
7. Challener, C. A. Sustainability by Design in the Context of Bioprocess Development. Pharm. Technol. 2025, 49 (4), 24–27.
8. Witte, C.; Perez, L.; Fernandez, M.; Weskamp, T. Decarbonizing API Manufacturing: Unpacking the Cost and Regulatory Requirements. McKinsey & Company. July 26, 2024. https://www.mckinsey.com/industries/life-sciences/our-insights/decarbonizing-api-manufacturing-unpacking-the-cost-and-regulatory-requirements
9. Lavery, P. How Smart Technology Is Helping Reach Sustainability Goals in Drug Packaging. Pharm. Technol.2025, 49 (5), 20–21.
10. Haigney, S. Supplying Sustainably. Pharm. Technol. Bio/Pharma Outsourcing Innovation eBook, February 2025, 20.

About the author

Susan Haigney is lead editor for Pharmaceutical Technology®.