Principles of green chemistry: Transforming pharma for sustainable drug production

The pharmaceutical industry, while essential for improving global health, has long grappled with significant environmental challenges arising from traditional chemical processes. As companies face increasing regulatory pressures and stakeholder expectations, the need for business sustainability strategies has never been greater. The principles of green chemistry provide a transformative approach, offering a pathway to reduce waste, minimise toxicity, and improve efficiency while fostering innovation. Keep reading as we dive into green chemistry and share some best practices for adoption within the pharma sector. 

What is green chemistry?

Green Chemistry is a scientific approach focused on designing products and processes that minimise or eliminate the use and generation of hazardous substances. Also known as sustainable chemistry, it seeks to reduce the environmental impact of chemical production while enhancing efficiency and safety.

Developed with the 12 Principles of Green Chemistry introduced by Paul Anastas and John Warner, this approach addresses challenges such as pollution, resource depletion, and toxicity in traditional chemical processes.

The 12 principles of green chemistry 

The 12 Principles of Green Chemistry provide a framework for designing chemical processes and products that are safer, more sustainable, and environmentally friendly. These principles aim to reduce waste, enhance efficiency, and minimise harmful impacts.

1. Prevent waste: It is better to prevent waste than to treat or clean up waste after it has been created.

2. Atom economy: Design synthetic methods to maximise the incorporation of all materials used in the process into the final product, reducing waste.

3. Less hazardous chemical syntheses: Design chemical processes that use and generate substances that are non-toxic or less hazardous to human health and the environment.

4. Design safer chemicals: Design products to be effective while minimising toxicity.

5. Safer solvents and auxiliaries: Avoid the use of auxiliary substances (e.g., solvents, separation agents), or use safer, non-toxic alternatives wherever possible.

6. Design for energy efficiency: Minimise energy requirements of chemical processes. Conduct reactions at ambient temperature and pressure when possible.

7. Use renewable feedstocks: Where possible, use renewable raw materials or feedstocks rather than depleting finite resources.

8. Reduce derivatives: Avoid unnecessary derivatisation (e.g., blocking or protecting groups), as it adds additional steps and generates more waste.

9. Catalysis: Use catalytic reactions (rather than stoichiometric reagents), as catalysts to reduce waste and improve efficiency.

10. Design for degradation: Design products to break down into non-toxic substances at the end of their life cycle, preventing environmental persistence.

11. Real-time analysis for pollution prevention: Develop analytical methodologies to monitor and control chemical processes in real-time, reducing the formation of hazardous substances.

12. Inherently safer chemistry for accident prevention: Choose substances and processes that minimise the risk of accidents, including explosions, fires, and toxic releases.

Benefits of green chemistry for the pharmaceutical industry

Green chemistry offers numerous benefits for the pharmaceutical industry, aligning environmental sustainability with operational efficiency and economic gains. Here are the key benefits:

Reduction of waste and costs

Green chemistry encourages processes that minimise hazardous and non-hazardous waste. By adopting atom-efficient reactions and reducing the use of solvents and reagents, pharmaceutical companies can lower waste disposal costs and save resources. For example, Pfizer achieved a 50 percent reduction in waste using green chemistry principles. 

Improved process efficiency

Green chemistry promotes atom economy and catalysis, leading to more efficient chemical reactions. This reduces the number of steps in drug synthesis, cutting down energy, time, and resources required for production. Fewer process steps mean reduced production costs and faster time-to-market for new drugs.

Safer products and processes

By designing safer chemicals and processes, green chemistry minimises the use of hazardous substances. This protects workers in pharmaceutical manufacturing, reduces risks of accidents, and ensures safer products for consumers. Moreover, it reduces exposure to harmful reagents, solvents, and by-products in manufacturing facilities.

Lower environmental impact

Green chemistry focuses on reducing emissions, water usage, and energy consumption. It promotes biodegradable chemicals and processes that leave a smaller ecological footprint. For example, Merck implemented green chemistry to redesign the synthesis of sitagliptin (a diabetes drug), reducing waste and eliminating hazardous reagents, while cutting water and energy usage significantly.

Compliance with regulations

Regulatory bodies are increasingly focused on environmental sustainability and safer chemical processes. Adopting green chemistry helps pharmaceutical companies comply with environmental standards like REACH (EU) and EPA regulations (US). This helps minimise regulatory risks and avoids costly fines or production delays.

Energy and resource savings

Green chemistry reduces energy requirements by enabling processes to run at ambient temperatures and pressures. It also promotes the use of renewable feedstocks, further decreasing reliance on finite resources. This reduces operational costs while enhancing sustainability. 

How to adopt the principles of green chemistry in pharma 

The below 6 strategies demonstrate how the pharmaceutical industry can embrace green chemistry to achieve sustainability objectives. 

#1 Adopt safer solvents and reaction conditions

Solvents contribute significantly to the environmental footprint of pharmaceutical manufacturing. By replacing hazardous solvents like dichloromethane and benzene with safer alternatives such as water, ethanol, or supercritical carbon dioxide, the industry can reduce toxicity, waste, and emissions. Additionally, solvent-free processes, like solid-state reactions, offer a cleaner and more sustainable approach to synthesis. 

#2 Leverage biocatalysis and enzymatic processes

Biocatalysis involves using enzymes or microorganisms as catalysts, enabling cleaner and more selective chemical transformations. Unlike traditional chemical processes that rely on toxic reagents and high energy, biocatalysis works under mild conditions, reducing energy consumption and waste generation. 

Companies like Merck have successfully applied enzyme-based processes, such as in the production of sitagliptin, to improve yield and eliminate hazardous by-products, showcasing the potential of biocatalysis in green chemistry.

#3 Implement Process Analytical Technology (PAT)

PAT allows real-time monitoring and optimisation of pharmaceutical manufacturing processes, ensuring greater efficiency and reduced resource usage. By incorporating advanced sensors and analytical tools, companies can detect deviations, optimise reaction conditions, and minimise waste. 

This proactive approach enhances product quality, reduces the overuse of reagents, and significantly cuts costs. The adoption of PAT is a critical strategy for aligning pharmaceutical operations with green chemistry principles.

#4 Optimise reaction efficiency and atom economy

Improving atom economy (the concept of using all atoms in starting materials to form the desired product) is a core principle of green chemistry. By designing reactions that minimise by-products and waste, pharmaceutical manufacturers can enhance resource efficiency. 

For example, using catalytic reactions instead of stoichiometric processes reduces material use and environmental impact. Companies adopting these practices see benefits in cost savings, waste reduction, and improved sustainability metrics.

#5 Transition to renewable feedstocks

Switching from petrochemical-derived inputs to renewable feedstocks, such as plant-based materials, reduces dependence on finite resources and lowers the carbon footprint. 

Bio-based precursors, like those derived from algae, agricultural waste, or plant oils, offer a sustainable alternative for drug synthesis. By investing in renewable resources, the pharmaceutical industry can ensure long-term sustainability while meeting growing environmental expectations.

#6 Integrate circular economy practices

Circular economy principles focus on reducing, reusing, and recycling resources within the manufacturing process. Pharmaceutical companies can recover and recycle solvents, repurpose waste by-products into valuable materials, and implement closed-loop systems to minimise resource loss. 

For example, solvent recovery technologies have proven effective in reducing both environmental impact and operational costs. Embracing circular practices ensures that pharmaceutical operations remain efficient, cost-effective, and environmentally responsible.

Conclusion

By embracing the principles of green chemistry, pharma companies can significantly reduce their environmental impact, enhance operational efficiency, and remain compliant with evolving regulations. Beyond environmental gains, these practices contribute to long-term resilience, cost savings, and a competitive edge in a sustainability-driven market.

To equip your organisation with the knowledge and tools to drive sustainable change, explore our online business sustainability courses. Learn how to implement forward-thinking strategies, reduce environmental footprints, and lead your industry towards a greener future. Join us in building a pharmaceutical sector that is both innovative and responsible.