SCHOTT Pharma, Takeda and Corplex have completed a full-batch shipment of pharmaceutical vials packed in trays that include recycled polypropylene, marking the move from trial work to regular operations.
The three companies have been working on a closed-loop recycling arrangement for pharmaceutical manufacturing to balance regulatory requirements.
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During the past two years, the partners carried out risk reviews, completed production studies at ton scale, and verified that trays made with recycled material matched the assessed performance of trays produced from virgin polypropylene.
Last month, the first full batch of vials using trays containing recycled material was sent to Takeda’s manufacturing facility in Singen, Germany.
Corplex fed the recovered material back into new tray production, while SCHOTT Pharma used the trays as intermediate packaging.
Takeda then completed change controls and manufacturing trials, which confirmed that the trays could be processed within pharmaceutical production.
The system can keep tray waste out of downcycling streams, incineration and landfill, while cutting dependence on fossil-based virgin polypropylene.
It introduces recycled content into intermediate packaging at industrial scale with equivalent assessed performance.
The closed-loop setup is linked to Scope 3, Category 1 emissions reductions across the supply chain, covering tray production by Corplex, use by SCHOTT Pharma as intermediate packaging, and shipment of vials to Takeda.
SCHOTT Pharma is preparing to roll out the recycling model to other pharmaceutical customers in Europe.
At present, it applies to standard packaging formats for 2R, 6R, 10R, 20R and 30R ISO vials.
The company is continuing work on expanding the scheme, including options for paper-labelled and coloured trays.
SCHOTT Pharma chief financial officer Reinhard Mayer said: “Moving from proof of concept to routine operations is a decisive step in commercialising circular economy approaches in pharma.
“This first full delivery demonstrates that we can uphold the industry’s uncompromising quality and patient‑safety standards while measurably improving resource efficiency and waste practice through controlled closed-loop recycling. Together with our partners, we are showing that innovation, environmental actions and compliance can reinforce one another.”
