What are pharmaceutical companies doing to improve the recyclability of their packaging?

What is the recyclability of packaging?

The recyclability of a packaging is defined by its ability to be recycled. More specifically, recyclability is defined according to 4 criteria:

• The raw material used: the packaging must be made from a material that is taken care of in recycling channels and has a market value and/or is supported by a program mandated by law.
• The ability to be sorted: the packaging must be designed to be easily sorted and directed to a recycling stream composed of a single type of material corresponding to the main raw material of which it is made.
• Recyclability: packaging must be able to be processed and recycled using commercial recycling processes.
• Raw material reusability: the recycled material must be able to become a raw material used in the production of new products.

It should be noted that various constraints can influence a packaging’s ability to be sorted and/or recycled. For example, packaging that is too small, a multi-material composition, the presence of labels or a packaging color that is too dark can disrupt both the sorting and recycling processes.

So, the recyclability of a packaging varies according to its adherence to these criteria. Various tools exist to assess the recyclability of packaging and thus predict its end-of-life. For example, the RecyClass tool available online assigns recyclability scores ranging from A to F, with an A score describing packaging that can be reused directly for the same purpose as its original use, and an F score describing packaging that cannot be recycled. In most cases, primary drug packaging tends to fall into the latter category, and work should therefore be carried out on its recyclability.

What can be done to improve the recyclability of pharmaceutical packaging?

Eco-design

Improving packaging recyclability is part of a global eco-design approach adopted by pharmaceutical manufacturers. This method aims to use raw materials and energy more rationally throughout the product life cycle, enabling companies to reduce their costs while minimizing their environmental impact.

Improving the recyclability of pharmaceutical packaging is part of this approach, leading to several considerations, including the choice of raw materials used. For example, it is preferable to use recyclable plastics such as PE, PET, PP and PS, rather than PVC, PLA and PC, which are difficult to recycle. Glass, on the other hand, can be recycled and is a good alternative to plastic. Another area for improvement is to make packaging mono-material as far as possible, with the presence of several materials within a single package. In addition, working on the structural characteristics of pharmaceutical packaging can help optimize sorting. For example, non-cylindrical packaging rolls less on sorting lines, which improves recyclability.

Many laboratories are committed to this eco-design approach. Sanofi has announced that all its new products will be eco-designed by 2025. CIPLA claims that 91.03% of the products it manufactures are already recovered, reused or recycled, and is committed to collecting pre- and post-consumer plastic for recycling, thus avoiding landfill.

Find out how we can support your efforts to improve the recyclability of your products >

Improving sorting and recycling lines or creating specific recycling channels

Improving the characteristics of pharmaceutical packaging can be limited by product-related constraints, preventing it from being taken up by conventional recycling channels. Non-modifiable factors such as too small a size, a complex composition with non-detachable multi-material elements, or hazardous parts such as needles are often the cause.

To compensate for this, companies can set up specific recycling channels for certain types of packaging, including dedicated collection channels, centralization of the packaging, and forwarding to specialized recycling operators. These players have suitable sorting and recycling chains, enabling all or part of the packaging to be recovered and reused in the manufacture of new products.

Novo Nordisk launched the ReturPen initiative in 2019 to recycle its disposable insulin injection pens. Initially rolled out in several countries, including Denmark, the UK and Brazil, followed by France in 2022, the program enables patients to return their used pens to pharmacies. These pens are then recycled into chairs and lamp globes thanks to partnerships with Danish design brands. Initial results show a return rate of around 20% in Denmark, with 77,000 pens recovered since the launch, representing 2 tons of plastic. In the UK, over 15,000 pens have been recycled since the launch of the pilot project in 2021. The aim is to recycle 50% of pens by 2030¹C:\Users\JDUMAS\Downloads\DP Returpen 15.12.2022 (4).pdf²https://www.novonordisk.fr/sustainable-business/Returpen.html.

Similar initiatives have been undertaken for pressurized metered dose inhalers (pMDIs), which cannot be recycled through conventional channels due to their multi-material composition and the presence of polluting residual gas. GSK, Chiesi and Teva have launched programs to recycle inhalers in the UK and Ireland. Inhalers are collected from pharmacies or by post and sent to Grundon Waste Management, a company specializing in the recycling of plastic, aluminum and gases. As with insulin pens, these initiatives make it possible to separate inhaler components for efficient recycling.

Waste management is one of the key issues in the sustainability approach adopted by pharmaceutical manufacturers. Working on the recyclability of pharmaceutical packaging is one of the levers for improving waste management and can involve improving packaging characteristics or creating new recycling channels to handle complex packaging.

But challenges remain. For packaging to be effectively recycled, it must be correctly arranged. But it’s not always easy for consumers to know where to put their packaging, especially when it comes to specialized recycling channels. Consumers don’t always make the effort to return their packaging to the right place.

It is therefore crucial to clearly communicate best practices to consumers, and to offer simple, diversified collection methods. Interaction between the various players – pharmaceutical manufacturers, packaging manufacturers, sorting and recycling operators – is essential to encourage innovation and maximize the effectiveness of communication. Keeping abreast of packaging innovations, including those from other industries, is also essential.

Alcimed can support you in monitoring the ecosystem and defining your strategies for managing end-of-life packaging in the pharmaceutical industry. Please do not hesitate to contact our team!

About the author,

Justine, Consultant with Alcimed’s Healthcare team in France.