Close the loop for pharmaceutical trays

Reduce tray-related GHG emissions and waste without compromising quality.​

The pharmaceutical industry has set ambitious sustainability targets, including decarbonization and improved resource efficiency. At the same time, pharmaceutical manufacturers and their suppliers must maintain high quality and safety standards. SCHOTT Pharma has pioneered and co-developed a closed loop recycling system for the plastic trays used to package and transport its drug containment solutions. Closed-loop in this context refers to the collection and recycling of used PP trays and the subsequent reuse of the resulting recyclate to manufacture new trays. Compared to trays manufactured entirely from virgin polypropylene, trays made with the tray-to-tray recycling system achieve measurable greenhouse gas (GHG) emission savings while ensuring uncompromised product quality.​

What if trays don’t end up at your waste yard?​

Together with Corplex, an expert in design, manufacturing, and recycling of transport packaging, and Takeda, a leading pharmaceutical company, SCHOTT Pharma established a closed‑loop recycling system for use in pharmaceutical manufacturing.​

​​By combining proven plastics recycling expertise with the stringent quality and safety requirements of pharma, the system is associated with measurable reductions in greenhouse gas (GHG) emissions compared to trays made entirely from virgin polypropylene, while maintaining product quality. ​

How the closed-loop recycling system works​

• Collection of used transport trays directly at the point of use​
• Inspection of incoming material to ensure strict control​
• Shredding of trays and production of granulate​
• Rebirth of new, high-quality trays from granulate​

By keeping materials in a controlled pharmaceutical closed loop, this approach delivers measurable environmental benefits.​

Results of an independent and peer-reviewed life cycle assessment​

Prepared by The LCA Centre for SCHOTT Pharma and Corplex in October 2024 and peer-reviewed by experts from University of Twente and Eco3 Design Ltd UK, an independent life cycle assessment provides robust evidence for the environmental benefit of closed-loop tray recycling in pharmaceutical supply chains. The study was conducted in line with ISO 14040 and ISO 14044 and applies the acknowledged IPCC Global Warming Potential standard (GWP 100a). It compares polypropylene trays made from virgin material with trays containing 70% recycled polypropylene sourced from a controlled closed-loop recycling system. The study confirms that for the trays analyzed greenhouse gas emissions were reduced by 51% versus trays made entirely from virgin polypropylene.​

The study scope covered the raw materials, tray manufacturing processes, associated transports and end-of-life scenario. Accounting for the cradle-to-gate plus end-of-life stages within the product life cycle, including tertiary packaging and transport for recycling. The compared trays adhere to the equivalent dimensional and functional specifications required for transport of glass vials from SCHOTT Pharma to Takeda in Germany. The filling stage and use stage of the glass vial have not been included, because it is the same for both trays and therefore not relevant for the study. The study followed a cut-off system methodology – any potential energy recovery from incineration was not included. Generic lifecycle impact assessment data from Ecoinvent v3.9.1 released in 2022 were applied. ​

In a highly regulated industry, intermediate packaging is traditionally designed around single-use practice and virgin material to minimize contamination risk and support traceability. The assessed closed-loop model shows that it is possible to improve resource efficiency while maintaining the intended packaging function and the high standards expected in pharmaceutical operations. ​

Ready to improve?​

We are ready to team up with the value chain to reduce GHG emissions without compromising product quality. Let’s multiply the use of our closed-loop recycling system! Here’s a simple pathway from pilot to routine operation:​