Sustainability is now a strategic imperative
As the biopharmaceutical industry scales up to meet global health demands, what are the hidden challenges in terms of plastic waste from single-use technologies (SUTs)?
A new BioPhorum paper, co-authored by PM Group’s Bulk Bio SME, Kevin Gibson, aims to shine a spotlight on this issue. It offers the first robust methodology to quantify SUT waste during monoclonal antibody (mAb) manufacturing.
Kevin led the development of the process model underpinning the study, enabling batch-level insights into how design decisions (like buffer preparation strategies and product titer) directly impact waste volumes. His work reveals that intermediate-scale facilities using traditional buffer prep can generate up to 370kg of plastic waste per batch.
This data is more than numbers, it’s a call to action. As sustainability becomes a strategic imperative, PM Group is helping clients embed circularity into facility design, optimise buffer systems and prepare for evolving regulations like the UN Global Plastics Treaty.
“This paper promotes the discussion of single-use plastic waste in biopharmaceutical manufacturing,” Kevin Gibson, Bulk Bio SME, PM Group notes. “It’s a vital first step toward designing for sustainability. PM Group is not just responding to the challenge, it’s helping shape the solution.”
Top 5 messages from the BioPhorum article:
- Single-use technologies (SUTs) are growing - and so is their waste - The adoption of SUTs in monoclonal antibody (mAb) manufacturing has increased due to benefits like reduced capital costs, faster time-to-market, and lower environmental footprint in some areas. However, this has led to a significant rise in high-specification plastic waste
- Quantification of Waste Is Now Possible and Actionable - The study provides a detailed, batch-level quantification of plastic waste generated during mAb production. For example, a 2,000L process using traditional buffer prep at 5g/L titer generates ~370 kg of plastic waste per batch
- Buffer Preparation Philosophy and Product Titer Are Key Waste Drivers - Buffer preparation methods (traditional, buffer concentrates, in-line prep) and product titer significantly influence waste volumes. Traditional methods tend to generate more waste
- Recycling Is Technically Feasible but Logistically Complex - Although the plastics used are high-value and recyclable, challenges like contamination, hazardous classification and lack of infrastructure hinder recycling efforts. Still, pilot programs and closed-loop systems show promise
- Collaboration and Data Sharing Are Essential - The paper advocates for multi-organisational collaboration to develop scalable recycling solutions and to align with global sustainability frameworks like the UN Global Plastics Treaty and ISO 14001
