An overview of a Life Cycle Assessment (LCA) study evaluating the environmental advantages of reusable versus single-use shippers for pharmaceuticals
by Minnesota Thermal Science
Reusable shippers result in less of an environmental impact versus single-use packaging for temperature-sensitive pharmaceutical products, especially at high volumes. That is the conclusion of a study undertaken in 2012 by thermal protection packaging provider Minnesota Thermal Science (MTS) in cooperation with The University of Minnesota College of Science & Engineering.
The fast growing pharmaceutical and biological markets serving an aging and growing population have spurred exponential demand for temperature-controlled packaging systems. To preserve and protect these critical payloads, the logistic system must provide strict thermally controlled environments during transport to locations around the globe. Global temperature-controlled transportation systems such as this can significantly increase the environmental footprint of these segments of the healthcare industry.
The challenge for the life sciences industry is that in an era of ever-growing transparency and a need for greater cost containment; sustainability is an important corporate initiative for major healthcare companies that need to protect temperature-sensitive payloads while reducing the environmental impact. MTS initiated this LCA research project with the objective of analyzing temperature-controlled packaging options and to compare their respective impact.
The Life Cycle Analysis research project investigated the environmental impact of MTS’ Credo Cube reusable shipper versus a single-use shipper with comparable payload volume and performance characteristics. The shippers were evaluated over a two-year period in a pharmaceutical clinical trial requiring 30,000 individual shipments within the continental U.S. The results of the study represent the cradle-to-grave carbon footprint comparison of the reusable, recyclable Credo Cube 12-L shipper with VIP/PCM (vacuum insulated panel/phase change material) components qualified to maintain a 2ºC to 8ºC temperature range for 96 hr with a single-use shipper insulated with either extruded polystyrene (EPS) or polyurethane (PUR) and gel packs.
During the study, the reusable containers were shipped twice a month, with a 90% annual recovery rate. The single-use model represented the average of the component weights of three leading producers of products supporting the functional unit. In terms of recycling, the Credo Cube had a 52% recycling rate, while 0% of the single-use components were able to be recycled, with the exception of the corrugated.
Sensitive payloads
The study results showed how the carbon footprint of transporting temperature-sensitive payloads, especially in high volumes, is significantly less with reusable, temperature-controlled containers in a closed-loop logistics system versus single-use technology. It was reported that the research results demonstrate that one of the greatest disadvantages of a single-use logistics system is the emissions generated in the first three phases—material extraction, component manufacturing, and component assembly—where 12 times the global warming potential is generated versus the reusable system. In addition, it was found with a closed-loop reverse logistics system in place, only 772 reusable shippers are needed over the two-year period, as compared to 30,000 shippers in a single-use container logistics system.
This differential significantly impacts the cradle-to-grave global warming potential, with the reusable container generating only 225 metric tons of emissions in comparison to 1,100 metric tons generated by EPS or PUR containers, according to t he study In addition, the reusable shipper generated just 7.3 metric tons post-consumer solid waste versus 157 and 194 metric tons for PUR and EPS, respectively, it was pointed out.
Over the course of 30,000 shipments, the study estimated that the reusable logistical approach reduces environmental impacts by the following:
- global warming emissions (GWP)—78%
- acidification emissions (AP)—66%
- eutrophication emissions (EP)—67%
- petrochemical ozone emissions (PCOP)—86%
- human toxicity emissions (HTP)—56%
- post-consumer waste—95%
Reusable packaging
Demonstrating the MTS/University of Minnesota results in a real-life application, one company, Eli Lilly, shows hard data from the company’s switch from single-use to reusable packaging for temperature-sensitive products.
Among the reported improvements in Eli Lilly’s system after adopting MTS’ Credo, the company:
- reduced the shippers used per order from 1.25 to 1.02, resulting in fewer boxes being handled
- increased the return rate of shippers from 0% for single use (in the U.S.) to 96% for reusable
- reduced freight costs by 32%
- reduced 424,400 lb of waste in first year
- saved $2 million annually.
In making the switch, Eli Lilly stated it moved from one size shipping case to four sizes, increasing payloads for cold-chain shipments. For the same payload capacity, he said, the company now uses containers with a 72% smaller outer diameter and 44% less weight.
IE/ME University of Minnesota, concludes that the Credo Cube shipper imposes less environmental burden in all five impact categories studied. The five-stage ‘cradle-to-grave’ life cycle impact comparison of the reusable shipper to a similar performance (volumetric capacity/duration) single-use shipper clearly demonstrated that the durable and reusable temperature-controlled container utilizing a closed loop logistics system significantly reduces the carbon footprint of transporting temperature sensitive payloads, especially in high volumes.