Designing Recyclable Healthcare Packaging for Medical Use

In response to escalating environmental concerns and the surging demand for plastics in healthcare, a pressing need has emerged for the advancement of recyclable plastics packaging. Packaging suppliers’ ability to innovate and meet evolving regulations across the value chain is crucial for overcoming challenges and driving sustainable progress. This has prompted a proactive shift among medical OEMs and thermoforming companies towards sustainable packaging solutions, waste reduction, and a heightened emphasis on recyclable materials. Pharmaceutical companies are also playing a key role in advancing sustainability initiatives, such as developing PVC-free blister packaging and implementing recycling programs to contribute to environmental goals.

According to the Healthcare Plastics Recycling Council, a staggering 32 billion pounds of healthcare plastics were manufactured globally in 2020, with projections indicating a rise to 48 billion pounds by 2025. Furthermore, a recent 2022 study at a hospital in Germany revealed that each patient generates 16kg of plastic packaging waste daily. Surprisingly, 80-85% of this waste is said to be clean and non-hazardous, making it theoretically recyclable. While healthcare facilities currently lack large-scale recycling systems, the industry, in collaboration with organizations like the Healthcare Plastics Recycling Council, is actively exploring avenues to establish effective plastic recycling initiatives.

With the strict requirements in place for safety, regulatory, and application standards, it is essential for companies to strategize and plan ahead to meet future recyclability goals. The complexity and challenges of meeting strict regulations in the pharmaceutical industry require identifying solutions that contribute to sustainability and address barriers along the value chain. Ongoing innovations in sustainable healthcare materials and the search for alternative materials beyond traditional plastics are also critical to advancing recyclable packaging. What steps can medical OEMs and thermoforming companies take today to enhance the recyclability of their rigid plastic packaging solutions in the medical, pharmaceutical, and healthcare sectors, and how can manufacturing practices and innovations further enhance recyclability and sustainability in the pharmaceutical industry?

Introduction to Medical Packaging Recycling

Medical packaging recycling has become a crucial focus within the healthcare industry, as hospitals and healthcare providers seek to reduce medical waste and promote sustainability. The Healthcare Plastics Recycling Council (HPRC) is at the forefront of these efforts, working to improve the recyclability of plastic products and packaging in healthcare settings. Sustainable packaging solutions are essential for medical devices, which require specialized packaging materials that not only protect the integrity and sterility of the devices but also minimize environmental impact.

Patient safety remains the top priority in medical packaging, and the use of recyclable materials such as high density polyethylene (HDPE) ensures that packaging can be both safe and environmentally responsible. The recycling process for medical packaging involves identifying which materials are recyclable, collecting them efficiently, and processing them into new products. This approach helps reduce the carbon footprint of the healthcare industry and supports a more circular economy, where valuable resources are reused rather than discarded. By focusing on recyclable packaging solutions, the industry can make significant strides in reducing medical waste and supporting sustainability goals.

Designing for Recyclability in Medical Packaging

While all thermoplastic materials may technically be “recyclable,” the true potential for effective recycling and reuse in new applications extends beyond just the type of plastic utilized. The actual recyclability of a material, on a practical and large-scale level, hinges on various factors such as consumer access to recycling systems, the market demand for recycled materials, the proper sorting capabilities at Material Recovery Facilities (MRFs) and Plastic Recovery Facilities (PRFs), and the capacity for the material to be processed into usable post-consumer recycled (PCR) feedstock. Additionally, the risk of contamination and the importance of managing direct contact between medication or medical devices and packaging materials must be addressed to ensure safety and compliance.

With the increasing concerns about plastic waste, organizations are actively developing guidelines and standards for design for recyclability to align stakeholders throughout the entire plastics value chain. These four organizations have established themselves as the go-to authorities for designing recyclable packaging, aiding companies in assessing the recyclability of their packaging solutions both now and in the future. Additionally, these organizations provide support to companies in meeting regulatory and sustainability goals:

• • APR Design Guide: The APR Design Guide is widely regarded as the go-to resource for designing recyclable plastics packaging in North America. It assists packaging designers in evaluating every aspect of their packaging, from the base resin and color to size, dimensions, closures, barrier layers, coatings, additives, labels, adhesives, and any other components. By measuring these elements against industry-accepted standards, the guide ensures that the packaging is truly compatible with recycling systems.APR categorizes packaging into four distinct groups: APR Design Preferred, Detrimental to Recycling, Renders the Package Non-Recyclable, and Requires Testing. According to the APR Design Guide, PET, HDPE, PE, and PP materials are deemed recyclable based on specific design elements, whereas PVC, EPS, PS, and PLA are classified as non-recyclable per APR standards. Paper is also increasingly being used as part of recyclable packaging systems, often in combination with plastics and aluminum, to enhance sustainability and meet circular economy initiatives.

  • US Plastics Pact Problematic & Unnecessary Materials List: The mission of the US Plastics Pact is to foster collaboration among public and private entities throughout the plastics value chain, sparking innovative approaches to designing, utilizing, and repurposing plastic materials. This collective effort aims to pave the way towards establishing a circular economy for plastics in the United States.
    
    The Pact collaborates with activator members to implement strategies aimed at phasing out a list of 11 problematic and unnecessary resins, components, and formats, with the goal of expediting this transition through collaboration. “Problematic or Unnecessary” is defined as “Plastic packaging items, components, or materials where consumption could be avoided through elimination, reuse or replacement and items that, post-consumption, commonly do not enter the recycling and/or composting systems, or where they do, are detrimental to the recycling or composting system due to their format, composition, or size.”

    The list goes on to name specific products and packaging materials to avoid or eliminate help guide organizations during the design or redesign phase including materials found in medical packaging including opaque or pigmented PET, PETG, PS, and PVC. When considering blister packs, there are significant challenges and questions of economic viability in transitioning to recyclable alternatives. Current initiatives in the pharmaceutical industry are exploring and evaluating examples of PVC-free blister packs, such as mono-polymer and aluminum-based solutions, to identify effective and sustainable options.

  • How2Recycle: How2Recycle strives to create clear and cohesive on-package labeling and disposal instructions for consumers in both the US and Canada, promoting transparency and consistency in recycling practices.

    Companies are encouraged to submit their complete packaging solutions, inclusive of over-wraps, caps/closures, and more, to the organization. The packaging is assigned a label based on one of four categories: Widely recyclable, check locally, store drop-off, and not yet recyclable. By incorporating this label on their packaging, companies can assist consumers in correctly recycling or disposing of the various packaging components. Additionally, providing clear examples and additional support helps companies comply with labeling requirements and improve consumer understanding.

  • Healthcare Plastics Recycling Council (HPRC): The HPRC has established Design Guidelines for Optimal Hospital Plastics Recycling. This guidance is aimed at influencing the design of plastic healthcare products and packaging to enhance recyclability while maintaining product integrity and performance. The recommendations provided focus on selecting preferred materials for mechanical recycling processes and exploring potential opportunities for advanced recycling technologies in the future. Packaging materials and formats are classified by preferred design aspects, based on qualities that facilitate recyclability. Materials like PET, HDPE and PP are considered “Preferred” materials that optimize recyclability for rigid thermoformed blisters and trays. PETG is considered “less preferred,” meaning that while this material does not optimize recyclability, the material has been proven to consistently meet product safety requirements. PS & PVC have been classified as “Not Preferred,” indicating that these materials do not optimize recyclability and should be avoided when possible. HPRC is also pioneering projects that address the challenge of ensuring device sterility and delivery effectiveness in various healthcare settings, including operating rooms.

Challenges in Medical Packaging Recycling

Despite the growing emphasis on sustainability, recycling medical packaging presents several unique challenges. One of the primary obstacles is the complexity of packaging materials used in the pharmaceutical industry and for medical devices. Medical packaging often consists of multiple layers—such as paper, plastics, and foil—designed to ensure product safety, extend shelf life, and maintain sterility. This complexity makes it difficult to separate and recycle the individual materials effectively.

Contamination is another significant challenge, as packaging that comes into direct contact with medication or medical devices can be difficult to recycle due to potential biohazard risks. The pharmaceutical industry has long relied on non-recyclable materials, such as blister packs, which combine plastics and aluminum foil in a way that complicates the recycling process. Additionally, the recycling infrastructure for medical packaging is often limited, and the cost of implementing specialized recycling systems can be prohibitive for many healthcare facilities.

Regulatory compliance adds another layer of complexity, as packaging must meet strict safety and quality standards, sometimes at the expense of recyclability. However, the industry is beginning to address these challenges through pioneering projects and innovations in packaging technology, which aim to improve the recyclability of medical packaging without compromising patient safety or product performance.

Recycling Solutions for Medical Packaging

To overcome the challenges of medical packaging recycling, the industry is embracing a range of innovative solutions. One promising approach is the design of packaging materials that are easier to recycle, such as mono-material packaging made from polyethylene or polypropylene. These materials simplify the recycling process and increase the likelihood that packaging will be successfully recycled and reused.

Closed-loop recycling systems are also gaining traction, allowing healthcare facilities to collect used packaging materials, recycle them, and incorporate the recycled content into new packaging solutions. The adoption of alternative materials, such as bioplastics or recyclable paper-based packaging, is being explored to further reduce the environmental impact of medical packaging.

In operating rooms, the use of recyclable sterilization wrap and trays—such as blue wrap made from polypropylene—demonstrates how current initiatives are minimizing waste and supporting sustainability. These materials can be collected after use and processed through established recycling channels, reducing the carbon footprint of healthcare operations.

Pioneering projects led by organizations like the Healthcare Plastics Recycling Council are driving innovation and collaboration across the industry. By identifying and minimizing challenges in the recycling process, these efforts are helping companies develop packaging solutions that support a more sustainable healthcare system. As more pharmaceutical companies and healthcare providers adopt these practices, the industry moves closer to achieving its goals of minimizing waste and promoting environmental stewardship.

The Future of Recyclable Medical Packaging

While the use of plastics in healthcare have resulted in countless lifesaving benefits, the resulting waste generated must be handled effectively in a way that enables the plastics circular economy, where plastics aren’t abandoned in landfills or scattered in our environment but are instead recycled efficiently when their product lifecycle ends. Recyclable health packaging can contribute to reducing environmental impact and benefit patients by ensuring both safety and sustainability. Through a robust recycling system, these materials can be reused into new applications, curbing landfill waste and reducing the demand for virgin plastic. Embracing design for recyclability is pivotal to realizing a circular economy for plastics. The circular economy for healthcare packaging relies on ongoing innovation and pioneering projects, such as those focused on developing new packaging technology for medicine and medication, to advance sustainability. The industry has long relied on non-recyclable materials in medical packaging, but is now transitioning to more sustainable options. Packaging also plays a critical role in maintaining the safety and effectiveness of medicine during transport, ensuring that medication reaches patients without compromising quality.

Interested in finding out how Impact Plastics can help you comply with industry-standard guidelines for recyclable medical packaging? Reach out to our team of experts to learn how we help our Medical OEM & thermoforming companies replace problematic and non-recyclable materials including PS with sustainable, recyclable & high-performance material solutions.

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