Interview with Victor Gherdan, Associate Director, Package Design
What are the primary challenges in implementing sustainable packaging for Drug-Device Combination Products (DDCPs)?
Sustainable packaging for DDCPs comes with unique challenges due to strict regulatory requirements and the critical need for patient safety. Packaging for injection devices, for example, must ensure sterility and provide protection from moisture, oxygen, and light. While biodegradable or recyclable materials sound promising, they often fall short in barrier properties or may interact with the drug product, risking degradation, chemical leaching, or could compromise efficacy.
With such stringent requirements, how does patient-centricity factor into the equation for sustainability?
That’s a crucial aspect. As the self-injection market grows, ease of use and disposal become even more important. For instance, patients with arthritis or reduced dexterity may struggle with alternative materials if they don’t offer sufficient grip or feel less durable. These factors can impact user confidence and, ultimately, treatment adherence.
What strategies can manufacturers adopt to balance these challenges with sustainability goals?
One effective approach is leveraging lifecycle assessments (LCAs) to identify environmental hotspots throughout the product lifecycle. From assessing the materials of device components and packaging to distribution to the end-user, companies can identify key areas of improvement that will have the greatest impact. At PCI, we guide clients to evaluate, test, and implement eco-friendly packaging solutions. For example, recyclable, paper-based secondary packaging can achieve the necessary performance while meeting sustainability standards. We also explore material optimization, such as using molded paper fiber trays instead of traditional plastic ones, which can reduce its global warming impact by up to 50%.
When is best to start planning on building sustainability into DDC product development?
Integrating LCAs into early development, alongside human factor studies, ensures patient compliance and product performance while enabling sustainable design choices. Compatibility between the drug product, container, and device must be assessed rigorously, as well as the performance of sustainable materials under various conditions. Early planning also helps identify and mitigate potential risks, addressing not only traditional concerns related to drug stability, device functionality, and adverse component interactions but also sustainability-specific factors, like the recyclability of materials, potential for contamination in reusable parts, and environmental impact of disposal.
What role does collaboration play in achieving sustainability goals?
Collaboration is key. Whether it’s within a pharmaceutical company or with Contract Development and Manufacturing Organizations (CDMOs), interdisciplinary teamwork ensures alignment between sustainability, compatibility, and performance. At PCI, we provide data-driven insights and rapid implementation solutions, helping clients meet their goals without compromising speed to market or cost-effectiveness.
Are there any significant advancements or methodologies driving sustainability in this space?
The optimization of packaging design itself is a game-changer. For example, resizing and reconfiguring secondary packaging recently resulted in a 30% size reduction for a client. This change not only improved environmental sustainability but also reduced storage and distribution costs. Quantifying benefits—like saving water, reducing gasoline use, or decreased cold chain space —helps businesses make informed decisions that align with their sustainability objectives.
What are your thoughts on the future of sustainable DDCP packaging?
The future holds immense potential. As sustainability becomes integral to business strategies, we’ll see more innovations like bio-based materials and advanced recycling technologies. The focus will also shift to comprehensive risk management, ensuring sustainability factors are as rigorously assessed as traditional concerns like product stability.
The industry is moving toward a greener future without sacrificing safety, efficacy, or usability. Companies embracing early integration of sustainability principles and collaborating effectively will lead this transformation. Together, we can deliver packaging solutions that meet regulatory standards, enhance user experience, and fulfill environmental responsibilities.
We are committed to supporting clients at every stage of the manufacturing cycle, delivering best-in-class services efficiently and effectively.
Find out more about our fully integrated Packaging Services.
