Maximum patient safety and the demand for environmentally friendly, recyclable solutions are putting pressure on the pharmaceutical industry. In this article, we take a look at PLA – a bio-based polymer – and its suitability as a future-proof material solution for drug delivery devices.
Marketing Authorization Holders (MAHs) are faced with a multitude of requirements: On one hand, there is increasing pressure to reduce environmental impact, lower the CO2 footprint, and eliminate critical substances such as BPA, DEHP, or PFAS. At the same time, the market demands reasonably priced and reliable products. And the EU is also tightening up regulations: requirements for reducing CO2, REACH, or the PPWR Regulation (Packaging and Packaging Waste Regulation) demand material compliance, the elimination of critical substances, and the combination of a circular economy and climate-friendliness. This is driving a shift in material selection. Because plastics used today will regularly no longer meet the requirements of the future.
Against this backdrop, manufacturers of drug delivery devices need to rethink their material choices. Is PLA a future-proof material solution? Let's take a closer look:
A small range of Medial Grade bioplastics are suitable for use in the healthcare sector. In this article, we focus on PLA. From our perspective, PLA offers a particularly great balance of technical performance, ergonomic advantages, and a low ecological footprint, including very flexible options for disposal and recycling. And at moderate costs, comparable to the plastics used today. It is recyclable, biocompatible, and low in CO2 —properties that make PLA a future-proof material solution. We will now take a closer look at these aspects:
Material properties
In particular the PLA-based BIOVOX MedEco ICB and BIOVOX MedEco IGH offer properties that are perfectly suited to the autoinjectors and inhalers of the future. Their high mechanical strength and stiffness ensure durable, reliable and material-efficient designs that reduce the use of plastics without compromising device integrity.
Both MedEco grades have higher stiffness than PC or ABS and are easy-flowing, enabling thinner parts that reduce cycle times, save material, lower costs and environmental impact. Low processing temperatures - approximately 50°C lower than ABS and 100°C lower than PC - also save energy.
All grades feature low shrinkage, high surface hardness and detail reproduction enable the production of highly precise components, which are critical for consistent performance of drug delivery devices.
BIOVOX MedEco ICB also offers very good crystal-clear transparency up to 1.5 mm wall thickness, making it ideal for components that require visual control of the drug or the dialed-in dose. If you need excellent transparency also at high wall thicknesses, BIOVOX MedEco ICB C1 with lower crystallization tendencies is a suitable choice.
Ergonomics: great tactile feel & safe handling
The haptics of the material further enhance perceived quality. Particularly, BIOVOX MedEco IGH offers a very premium tactile feel plus excellent grip with vinyl and nitrile gloves, both wet and dry, and a premium experience when patients handle autoinjectors directly —clearly outperforming the waxy feel of conventional polypropylene.
Energy consumption & CO2 footprint
FüPLA requires minimal energy to produce the polymer, with a cradle-to-gate footprint of only about 0.6 kg CO2e per kg of BIOVOX MedEco ICB The materials are fossil-free, which also reduces dependence on fossil resources from politically critical regions.
This means up to 85% lower carbon emissions, including the currently most common incineration at the end of their life, compared to materials like fossil based virign PP, ABS or PC.
Recycling & other End-of-Life Options
PLA is one of the most versatile polymers when it comes to disposal. It performs better than fossil-based plastics in all common disposal scenarios – and is therefore future-proof. PLA is carbon neutral when burned, as the released CO2 was previously bound by the plants. If it is deposited, it does not release any pollutants and decomposes biologically – significantly less critical than PP, ABS or PC. PLA is also industrially recyclable: It can be reliably detected, sorted, and mechanically recycled. Chemical recycling is also possible – with high yield and low energy consumption. This results in a new high-quality chemical rPLA with half the CO2 footprint compared to new material. With complete security, traceability, and performance.
Figure 1: Carbon footprints of plastics used in drug delivery devices (updated data with further reduced CO2 values will be available soon – >>contact us!)
Even though some perceive PLA as an expensive niche polymer, the facts tell a different story: In most of our projects, we observe only a minor 5-10% increase in parts cost while reducing the carbon footprint by 60-85% and eliminating regulatory risks due to critical substances such as BPA and others. Having mitigated several health- and market access risks while contributing to the MAH’s ESG ratings and gaining marketing opportunities is a very good investment in our eyes.
Download our >>whitepaper related to this article now!
The need for change comes from different sources/reasons like patient safety, the markets pharmaceutical companies operate in and Planetary Health, but also a lot of new legislation. Those who wait too long to change might stay behind and risk their market access in progressive countries. New solutions have to be found and bioplastics in Medical Grade quality are a suitable option. By implementing sustainable materials such as BIOVOX MedEco ICB or IGH, manufacturers can future-proof their products and stay ahead of the competition. With EU regulations driving sustainability and the industry already moving towards circularity, now is the time to innovate.
Do you want to make an application in the field of drug delivery devices future-proof? Please do not hesitate to contact us!
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