Sustainability is no longer a buzzword; it’s a necessity, especially in industries with significant environmental impact, like pharmaceutical manufacturing. But what does sustainability look like in pharmaceutical manufacturing? How can companies transform their processes to align with environmental priorities, while maintaining product quality and consistency?

Sealing Pharma Manufacturing Sustainability

Reducing maintenance costs and environmental waste is a priority for sustainable pharma processes. Seals and components may seem like small pieces in large-scale pharmaceutical manufacturing systems. However, their performance directly influences safety, efficiency, and sustainability. "When it comes to pharmaceutical manufacturing, reliability and performance are non-negotiable. Our FFKM elastomer Chemraz® is designed to provide peace of mind by delivering unmatched durable seals for applications that can’t fail even in the most demanding pharma manufacturing conditions," says Rich Dilorio Jr, Business Development Manager at Greene Tweed. One example of this is Chemraz® SD 625, which is FDA and USP Class VI certified to minimize contamination and ensure the integrity of manufactured products.

He goes on to say that reducing maintenance and waste is key to improving sustainability in pharma processes, and Chemraz® can make a significant difference by offering superior chemical resistance and durability compared to traditional options like EPDM or encapsulated seals. For instance, a global pharmaceutical plant faced challenges with its original fluorinated ethylene propylene (FEP) encapsulated seals, which struggled to endure the harsh conditions within autoclaves. These seals frequently degraded due to repeated cycling under extreme fluctuations in temperature and pressure, while being exposed to harsh fluids such as steam, chilled water, and compressed air. The frequent failures led to a maintenance cycle of less than one year, increasing downtime, contamination risks, and environmental waste.

 The introduction of Chemraz® seals from Greene Tweed solved these challenges. Designed to endure harsh operating conditions, Chemraz® provided exceptional resistance to extreme temperatures and aggressive chemicals. After switching to Chemraz®, the seals lasted over five years without any performance issues, significantly improving the plant’s maintenance cycle. This not only reduced the frequency and cost of maintenance but also minimized contamination risks and environmental waste, ensuring smoother operations and greater reliability.

By replacing the failing seals with Chemraz®, the plant achieved a more sustainable and efficient solution, proving the value of advanced sealing technology in high-stress environments.

 Why Is Sustainability Crucial in Pharma Manufacturing?

• Lower Environmental Impact of Pharmaceuticals: Pharmaceutical manufacturing leaves a significant footprint due to the resource-intensive processes involved. From energy consumption to chemical waste, production lines, especially in legacy plants, can generate high emissions and environmental pollution. Sustainable practices and materials can help reduce energy use, emissions, and waste, ensuring a smaller environmental footprint at every stage of production.
• Regulatory and Consumer Pressure: Governments and regulatory bodies globally are imposing stricter environmental standards on pharmaceutical manufacturers. Consumers, increasingly aware of environmental issues, demand more transparency and responsibility. Companies failing to meet these expectations risk losing trust, competitive positioning, and market share.
• Long-Term Cost Efficiency: While longer-lasting and high-performing materials may involve higher upfront costs, the long-term savings often outweigh the initial investment. Reduced energy usage, lower waste management costs, and optimized processes lead to better financial outcomes.

Are your pharmaceutical manufacturing operations growing increasingly complex and challenging to manage sustainably? Connect with a Greene Tweed representative to discover how our FDA Class VI FFKM sealing solutions can enhance the safety, efficiency, and reliability of your processes—ensuring the integrity of your medicines every step of the way.

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