Technology that enables the transition to sustainable packaging
Sustainability is no longer a secondary concern in pharmaceutical manufacturing. Increasing regulatory requirements, growing ESG ambitions, and heightened expectations from patients and stakeholders are driving change across the entire value chain.
At PPS, we are seeing both frontrunners and followers. While some manufacturers are already replacing legacy packaging lines to enable the use of recyclable mono-materials, others are still in the early evaluation phase. One thing is certain: the transition is underway. And the right technology partnerships make all the difference.
Advanced digital print for mono-materials: WebJet H903 by Hapa
One of the technical hurdles in sustainable packaging is the ability to print directly on new materials, such as polypropylene (PP), polyethylene (PE), and polyethylene terephthalate (PET). These materials are recyclable and increasingly preferred in blister packaging; however, their surface properties present challenges for conventional printing methods.
Hapa’s new WebJet H903 directly addresses this challenge. The system enables two-color digital print on PP, PE, PET, and aluminum-based blister foils with high precision and minimal waste. Designed for inline or near-line integration, the WebJet H903 is ideal for pharmaceutical environments where traceability, print integrity, and flexibility are critical.
Benefits of the H903 include:
- Minimal set-up waste and no need for pre-printed stock
- Compatibility with mono-materials and foil-based substrates
- Fast changeovers and low downtime for higher OEE
- Support for late-stage customization with serialized data
- Moisture- and temperature-resistant UV DOD inks
This makes it an optimal solution for pharma manufacturers seeking to reduce their environmental impact without compromising compliance or production efficiency.
IMA’s sustainable packaging approach: engineered for recyclability
As a global leader in packaging technology, IMA has embedded sustainability into every level of machine design through its IMA Zero initiative. One key outcome of this program is the ability to support mono-material blister films, such as the PharmaGuard solution developed with Südpack. These PP-based films offer the barrier performance needed in pharmaceutical applications, but with significantly improved recyclability.
IMA’s blister machines are developed with sustainability and GMP in mind. Key features include:
- Precision forming and sealing systems for recyclable plastics
- Minimal start-up material requirements and tight pocket layouts
- Energy-efficient drives and heating elements
- Compatibility with recycled cardboard and plastic-free trays
- Full integration with track & trace and vision systems
IMA also manufactures carton erecting and sealing systems designed for recycled board, ensuring that both primary and secondary packaging can be optimized for lower environmental impact.
Importantly, all new IMA lines are developed with the upcoming EU Packaging and Packaging Waste Regulation (PPWR 2025/40) in mind, ensuring long-term compliance and performance.
How PPS supports the transition
With over two decades of experience in the pharmaceutical industry, PPS combines technical expertise with strong supplier partnerships to deliver complete, future-proof solutions. Through close collaboration with our suppliers and in-house automation specialists, we help customers take the next step towards sustainability by:
- Reducing material waste and energy use through smarter equipment choices
- Integrating late-stage customization to support shorter time-to-market
- Adopting recyclable packaging without sacrificing product protection
- Ensuring compliance with future EU packaging regulations
- Optimizing total cost of ownership with long-life, low-waste systems
Whether you are planning a full packaging line upgrade or evaluating sustainable options for a new product, PPS can help you reduce complexity, accelerate implementation, and meet your ESG goals, without compromising operational performance.
Looking to make your packaging future-ready?
Let’s talk about how PPS can help you transition to sustainable, compliant, and cost-effective solutions.