Committing to a Sustainable Future in Biomanufacturing
With an increasing spotlight on sustainability, it is increasingly important for industry-wide sustainability practices to be implemented to ensure transformative change is achieved.
While the biopharmaceutical industry is pivotal in helping to improve the health and wellbeing of the global population, it is also a significant contributor to global carbon emissions. According to a 2019 study, performed by Health Care Without Harm (HCWH), the healthcare industry contributes to 4.4% of global net emissions of carbon dioxide, which is equivalent to the annual greenhouse gas emissions from 524 coal-fired power plants (1).
In 2022, My Green Lab released its report that specifically evaluated the upstream and downstream value chain of biotech and pharma, quantifying the scope 3 emissions for public and private companies in the sector (2). Key findings from this study were that, while the larger companies had established climate goals and were reducing scope 1, 2, and 3 emissions, the vast majority of public companies were not aligned with a 1.5 ºC world. These findings indicate that more ambitious climate change and sustainability targets need to be set by industry.
“As climate change takes centre stage in global affairs, the pharmaceutical industry can no longer afford to ignore the imperative of sustainability,” affirms Vinay Saluja, Global Head Development Services, Novartis Contract Manufacturing. “The actions of major players, like Novartis, set the tone for how the sector responds to mounting environmental demands.”
Considering Sustainability Challenges
“Sustainability in biomanufacturing operates on two critical levels: organizational resilience and environmental responsibility. Both present unique challenges that require strategic thinking rather than quick fixes,” explains Scott Broughton, CCO, Ascend.
In terms of organizational sustainability, biomanufacturing companies considered to be the most sustainable share common characteristics, such as efficient operations, lean processes, and strong leadership, Broughton continues. “These organizations maintain the flexibility to innovate and pivot quickly — capabilities that larger, more rigid companies often lack,” he says. “When companies invest in the right people and cultivate an entrepreneurial ‘get it done’ culture, they create the foundation for long-term sustainability in an industry that's rapidly maturing while being pressured to deliver increasingly complex products.”
Across the European Union, sustainability came into regulations along with the omnibus package of other regulations — the Corporate Sustainability Reporting Directive (3) forming a cornerstone of the European Green Deal (3) — remarks Haans-Christian Mahler, CEO, ten23 health. However, for Mahler the requirements being enforced are not rigorous enough.
“Sustainability should be considered from a ‘company’ and ‘facility’ view but also from a ‘product’ view,” Mahler continues. “When working with suppliers, like CMOs, chose a supplier that operates neutrally related to CO2emissions, rather than working with a CMO who is just ‘measuring’. Also, think beyond CO2 in any case. There are many elements of your facility you can fix quickly, in order to move towards becoming more sustainable.”
Single-Use Technologies: A Key Advancement
A key advancement within biomanufacturing over recent years has been the implementation of single-use systems, asserts Minni Aswath, VP of Process Development, Bionova. “[Single-use technologies] reduce contamination risk, increase flexibility, and lower cleaning validation costs,” she says.
“Single-use systems also help with sustainability,” adds Steve Lavezoli, VP, Curia Biologics at Curia Global. “Although they require careful oversight and management, these can reduce cleaning and sterilization needs.”
By way of example, Lavezoli points out that the reduced requirement for cleaning and sterilization are reasons that Curia regularly uses single-use systems. Additionally, he notes that many single-use system components can be recycled, adding to the sustainability benefits.
“In the era of single use technologies, sustainability efforts should prioritize efficiency and waste reduction. Achieving this begins with well-designed procedures and a ‘right-the-first-time’ approach to manufacturing implementation,” confirms Magdalena Leszczyniecka, CEO of STC Biologics. “By minimizing rework and maximizing the utility of every assay and production run, organizations can significantly reduce material and energy consumption.”
Strategic Supply Chain Management
“Equally important is strategic supply chain management,” Leszczyniecka says. “Collaborating with local suppliers to reduce transportation emissions or selecting vendors committed to sustainable practices, such as using recycled materials for packaging, can further support green initiatives.”
Companies need to be thinking outside of direct operations when it comes to improving supply chain sustainability, agrees Saluja. “With over 90% of emissions embedded within the value chain, it is both strategic and necessary for companies, such as Novartis, to embed Environmental Sustainability Criteria into supplier contracts,” he says.
“Collaborative efforts with suppliers signal a new era of accountability, where cutting emissions becomes a shared responsibility rather than an afterthought,” continues Saluja. “In this way, Novartis, and other industry players, are not just adapting to the future — they are helping to shape it.”
Cultural Commitment
“Biomanufacturing sustainability is achieved through sustained focus on minimizing environmental impact while improving efficiency and productivity,” remarks Paul Bird, Senior Director, Quality Assurance, FUJIFILM Biotechnologies. “This sustainability mindset is rooted in and best developed out of a culture of operational excellence which continuously generates simple and standardized patient-focused processes.”
Focusing on the chemical manufacture of small interfering RNA (siRNA) therapeutics, Alison Moore, Chief Technical Officer, Codexis, points out that large volumes of the toxic and flammable solvent, acetonitrile, are required. “In addition to being dangerous for those handling it, this leads to significant volumes of hazardous waste, which adds both cost and environmental burden to the process,” she notes. “Solvent use also generates byproducts and impurities that necessitate extensive purification steps in order to result in a high-purity therapeutic.”
To overcome these issues, Codexis uses an aqueous based platform that employs enzymatic methods instead of chemical processes to reduce the amount of solvent required and reduce downstream purification steps, Moore continues. As a result, harmful environmental and cost impacts of the chemical manufacture of siRNA can be reduced, she specifies.
“Sustainability is also a cultural commitment,” adds Leszczyniecka. “Training employees to recognize and eliminate waste in everyday tasks, and encouraging attention to small, incremental improvements, fosters habits that translate into long-term impact. These ‘small wins’ not only benefit the environment but also drive operational efficiency.”
Achieving Transformative Change
“The word ‘quick’ doesn’t always translate in biomanufacturing, whether it be a tech transfer, scale-up, or sustainability initiatives,” remarks Lavezoli. “While next generation technologies could provide quick solutions in the future, currently the lack of track record prevents them from being completely viable solutions for sustainability. However, we are already seeing how those technologies, like AI and continuous manufacturing, could streamline processes, leading to less waste and greater efficiency.”
While not unique to the biomanufacturing sector, green energy is a practice that can enhance sustainability across the board, Lavezoli continues. “[Green energy] is often a great alternative to standard energy sources in emergency situations where blackouts can occur,” he says.
“Looking to the future, biologic manufacturers can explore the use of renewable materials, such as biodegradable plastics, and invest in renewable energy sources like solar power,” agrees Leszczyniecka. “Facilities can optimize sustainability by incorporating energy efficient infrastructure such as LED lighting and optimized HVAC systems, and by considering continuous manufacturing approaches that operate in smaller, more flexible footprints.”
Additionally, it is possible to further reduce waste through considered reuse of materials, obviously ensuring contamination risks are mitigated, Leszczyniecka points out. “Together, these strategies contribute to a more sustainable model of biomanufacturing — one that balances innovation, regulatory compliance, and environmental responsibility,” she specifies.
“True sustainability improvements require bold leadership and industry-wide commitment,” concludes Broughton. “While individual companies can make meaningful progress, transformative change requires industry-wide adoption of sustainability practices.”
References
HCWH in collaboration with Arup. Health Care’s Climate Footprint. Report, September 2019.
My Green Lab. The Carbon Impact of Biotech & Pharma. Report, November 2022.
European Commission. Corporate Sustainability Reporting. EC.europa.eu, accessed Aug. 1, 2025.
European Commission. The European Green Deal. Commission.europa.eu, accessed Aug. 1, 2025.