Efficiency: The Key To Sustainable Manufacturing In Pharma

Applied in the context of business sustainability, this notion of striving towards true efficiency is appealing for many. However, sustainability applied in the environmental context, in regards to the sector’s impact on the world’s resources, is also of increasing concern. Though, it certainly comes with its challenges.

When considering just pharmaceutical packaging, industry leaders note difficulty when considering recyclable materials. Most of the materials used in pharma manufacturing must achieve the required barrier properties to contain medicinal drugs and as a result, many recycling companies are reluctant to process them due to the active pharma ingredients they contain. Research into sourcing a material that can be effectively recycled is ongoing, yet the process of pushing innovative new packaging systems through regulatory tests can take time.

The growing industry-wide interest in achieving a circular economy calls for a more ecologically sustainable system that in turn, could also bring economical benefits too. As a result, many in the pharma sector are now looking to invest in solutions that can provide the type of leading efficiency required to drive a global shift towards a more sustainable future.

Unfortunately, there is no ‘one size fits all’ solution. But there are a few essential steps pharma teams can take to encourage efficient and sustainable manufacturing processes across the board.

Reducing the margin for error

Any production line that is prone to mistakes is also prone to wastage. Production errors don’t only use up unnecessary resources, requiring the product to be destroyed and replacements to be made, but they can also cause huge delays when costly recall procedures are required, extending timescales for production.

While some recalls may be due to mistakes that have been spotted in the R&D process, such as the recent Dr Reddy’s Laboratories recall; responsibility for many other high profile recalls including International Laboratories’ 2018 mislabelling incident lies firmly with the manufacturer.

Of course, high standards of decision-making from an expert with years of insight are invaluable for production, however, a certain element of human error will be unavoidable. Investing in tools such as APS software though can help to minimise the recall risk thanks to precision planning algorithms. They also empower knowledgeable planners to make key decisions and adjustments where necessary. Production managers can spot manufacturing mistakes before they happen, helping to reduce the need for costly recalls.

Get data-savvy

Errors can certainly be costly for pharma businesses especially when you factor in the cost of wasted materials and resources and having to manufacture new batches. However, having access to key data will not only help drive efficiencies, but could be the key to mass waste reductions.

Tools such as Orchestrate use data from multiple sources to analyse and produce efficient production models, maximising the best use of - often rare and expensive - materials and reducing any unnecessary wastage. With this insight, even initial orders of bulk components and raw materials can be adjusted to better suit the needs of each product line.

There are other ways to utilise resources too, with developments such as ‘pigging’ technology ensuring no liquid is wasted. Alongside this, being armed with visibility over the tasks that share resources such as clean-in-place and steam-in-place, for example, which tend to share capacity and resources like water for injection (WFI), can also boost efficiency. If a bottleneck occurs and one part is delayed, the knock-on effect of the wasted WFI can add up to huge costs for a company.

APS software offers insight into every step of the production line, helping the management of resources and stock without the need for manually updated spreadsheets, so products can be ordered just in time to reduce stockpiling. And with the help of ‘what if’ planning, any bottlenecks can be predicted and mitigated quickly, reducing their negative impact.

Cloud-based server and online connectivity

Switching to an application that uses cloud-based technology is also an increasingly popular sustainable and energy-efficient solution for many. A study of global data centres earlier this year found that, even though computing output had risen sixfold over the period of eight years, energy consumption surprisingly only rose by six percent - a factor largely accepted to be down to the shift to cloud computing.

Compared to traditional servers based on-premise, the encrypted tools are much more secure and enable quick communication and connectivity. In addition, with no need for on-site servers that require maintenance, teams can focus on the key tasks that matter most to the business.

With more and more companies now adapting to the new reality of working from home, using a cloud-based planning system means that certain planning tasks can still be performed from a range of different locations. Offering quick and easy integration, Orchestrate provides real-time updates to all stakeholders and reduces the need for administrative procedures.

As the world becomes ever more environmentally conscious, the need to develop efficient, yet sustainable pharmaceutical manufacturing processes has never been more important. Data insights and adaptability will hold the key, as the latest tech applications drive real change.