Use of PCR plastic in pharmaceutical packaging is becoming an important step towards a circular economy.
The answer is yes, you can use PCR plastic in pharma, but only as a secondary and tertiary packaging materials.
In pharmaceuticals, safety comes first.
Medicines are sensitive and any packaging material that directly touches the drug must be in the purest form.
PCR plastic contains impurities, so it is not recommended to use as a primary packaging material, especially for injectable medicines, where the drug directly goes to the bloodstream.
However, with the advancements in recycling technologies followed by rigorous testing, there is growing potential to use PCR plastic in certain pharmaceutical dosage form.
For example, products such as tablets, capsules, creams and ointments generally have a low risk as compared to liquid and injectable medicines.
At the same time, there is also an increasing focus on other sustainable packaging materials such as corn starch-based plastics and seaweed-based packaging.
These materials are biodegradable and environmentally friendly, but they have certain limitations in pharmaceutical packaging due to poor barrier properties and shorter shelf life.
Today, pharmaceutical packaging contributes significantly to plastic waste.
The biopharmaceutical industry alone generates around 300 million tonnes of plastic waste annually, with a large portion coming from single use packaging.
In this blog post, we will take a closer look at PCR plastic—what it is, its types, recycling processes, benefits, challenges and its future possibilities in pharmaceutical packaging.
What is PCR Plastic?
In simple terms, PCR is Post-Consumer Recycled Plastic.
This plastic is made from plastic waste or materials that have been already used by consumers and then collected, processed and recycled into new products.
Common plastic waste include:
- Water bottles.
- Shampoo and detergent bottles.
- Food containers.
- Household plastic waste.
Plastic Waste Classification
Instead of sending plastic waste to landfills, it can be recycled and reused to create new packaging materials.
However, not all plastics are recycled, today.
Plastic waste is generally classified based on the type of resin.
Code | Polymer Resin | Example | Recyclability |
1 | PET | Cough Syrup Bottle | High |
2 | HDPE | Tablets in Bottle Pack | High |
3 | PVC | Blister Pack | Difficult |
4 | LDPE | Bags | Limited |
5 | PP | Caps | Improving |
6 | PS | Trays | Low |
7 | Other | Laminate | Very Difficult |
Among these, PET (Polyethylene Terephthalate) and HDPE (High-Density Polyethylene) are the most commonly recycled plastics.
These materials are widely used in bottles and containers and can be processed into high-quality PCR plastic.
Because of their cleaner recycling streams and better traceability, they are considered suitable for food packaging and, in certain cases, for pharmaceutical packaging.
Other plastics such as PVC, LDPE and PP can also be recycled, but the process is more complex and costly.
Their quality after recycling may vary due to impurities or mixed material sources.
At last, multi-layer plastics and composite materials, such as blister packs and laminates, are nearly impossible to recycle.
These laminates are made by fusing different materials together that cannot be easily separated, making them unsuitable for producing high-quality PCR plastic.
PCR Plastic Recycling Processes
PCR plastic is produced through two main recycling methods.
1. Mechanical Recycling
This method is most widely used, today.
The process includes:
- Sorting (using AI and infrared cameras).
- Shredding.
- Cleaning and washing.
- Drying.
- Melting and extrusion.
But this process has some limitations:
- The quality is lower than virgin plastic.
- Contains impurities due to mixed plastic waste.
- Residual chemicals may be present, like BPA or phthalates.
Because of this, mechanically recycled PCR plastic is not useful as a primary packaging material.
Important Notes: To improve safety, strict testing is required, such as:
Migration Testing
Migration testing checks whether any chemicals from the plastic material move into the product over time or not.
- The packaging is exposed to controlled conditions (temperature, time, solvents).
- It simulates real storage conditions like long-term and accelerated stability.
- The number of substances migrating into the product is tested.
Migration Modelling
Migration modelling is a theoretical or predictive approach used to test material, like stress study at 50° C & 80 %RH.
- It uses scientific equations to estimate how much substance could migrate.
- Helps to predict long-term behaviour without running lengthy experiments.
- Useful for evaluating worst-case scenarios.
This reduces testing time and supports risk assessment during development stage.
Surrogate Contamination Testing
This test evaluates how well the recycling process removes the contaminants.
- Known chemicals (called surrogates) are intentionally added to plastic waste.
- The recycling process is applied.
- The reduction in these contaminants is measured.
If the process removes these model contaminants effectively, it is considered safe for use.
2. Chemical Recycling (Advanced Recycling)
Chemical recycling is a new technology.
Know more on chemical recycling here.
In this process:
- Plastic is broken down into its original building blocks (monomers) with the help of chemicals.
- Then it is used to create high-quality plastic, resulting materials are very similar to virgin plastic.
Because of its purity, this type of PCR plastic can be used for food and pharmaceutical packaging.
However, there are challenges:
- It is under lab scale.
- It requires high investment and chemicals.
- Environmental impact (LCA) needs to check.
Note: Minimum 5–10 years is required for full scale implementation.
How Can We Use PCR Plastic in Pharmaceutical Packaging?
A practical approach for using PCR plastic in pharmaceutical packaging is to blend it with virgin plastic.
For example:
- 30% PCR plastic.
- 70% virgin plastic.
In such combination:
- Virgin material is used on the inner layer where product will come in contact.
- PCR material is used in the outer layer of the material.
This reduces the risk of contamination while still supporting sustainability goals.
Important Note:
Before using PCR plastic, companies must perform:
- Risk assessment.
- Stability studies.
These studies include:
- Long-term stability (25°C / 65% RH).
- Accelerated stability (40°C / 75% RH).
- Stress conditions (50°C / 80% RH).
Testing must be as per targeted market/country.
Examples of PCR Plastic in Pharmaceutical Packaging
Even though PCR plastic in pharmaceutical packaging is still evolving, several companies and industry initiatives have already started using it in practical ways.
1. Otsuka Pharmaceutical
The Implementation: This global Japanese healthcare company rolled out 100% recycled PET (r-PET) resin bottles across its massive consumer health portfolios.
The Impact: They utilize high-purification mechanical and advanced recycling streams to entirely bypass the need for virgin fossil-fuel plastics in their commercial product lines.
2. Jamp Pharma
The Implementation: Jamp Pharma Group’s Wampole division completely switched its conventional primary medication containers to bottles crafted from 30% to 100% post-consumer recycled (PCR) plastic.
The Impact: This move represented one of the very first large-scale transitions to high-percentage PCR materials for primary over-the-counter and natural health retail lines in the Canadian pharmaceutical market.
3. Chiesi Group
The Implementation: Chiesi Group successfully integrated ultra-pure 100% recycled loop PET resin into their commercial liquid medication primary packaging.
The Impact: Developed alongside strategic packaging providers, the PCR bottles undergo rigid molecular stripping to achieve zero toxicologically relevant extractables, guaranteeing absolute safety for patient ingestion.
These examples clearly show that PCR plastic in pharmaceutical packaging is already being used in a safe and controlled way and its application will continue to grow as technology and regulations evolve over the time.
Regulations for PCR Plastic
Currently, there are some regulations for food packaging in countries like:
- European Union (EU).
- United States (US).
Manufacturers must submit safety data and get the approval for market launch.
However, for pharmaceuticals:
- There are no specific global regulations for PCR plastic packaging.
- This is due to drug safety.
Until regulations are clearly defined, companies should rely on:
- Internal quality standards.
- Scientific risk assessment.
- Stability and migration studies.
- Secondary packaging.
- OTC and topical packaging.
Benefits of PCR Plastic in Pharmaceutical Packaging
Using PCR plastic offers several environmental and economic benefits:
1. Waste Reduction
Using recycled plastic, we can reduce the plastic waste going to landfills and oceans.
2. Lower Carbon Emissions
PCR plastic typically has a lower carbon footprint (70-80%) compared to virgin plastic production.
3. Reduced Use of Natural Resources
It reduces dependence on fossil fuels and raw materials.
4. Supports Circular Economy
PCR plastic promotes reuse and recycling of plastic waste, creating a closed-loop system.
5. Improves Brand Image
Pharma companies that are adopting sustainability practices gain trust and recognition among customers, regulators and stakeholders.
By using PCR plastic in pharma packaging, companies can also improve their ESG (Environmental, Social and Governance) scores, which are increasingly important for investors and global compliance.
In a crowded and competitive market, this helps to enhance brand value and differentiate the company as a responsible and future focused organisation.
Challenges of Using PCR Plastic
Despite the benefits, there are several challenges:
1. No Standard Specification
There is no set of global standard for PCR plastic for pharmaceutical use.
2. Material Quality
PCR plastic quality can vary:
- From batch to batch.
- From one supplier to another.
3. Risk of Migration
PCR plastic has more Impurities than virgin plastic, so chances of migration/leachability is more, especially in long-term storage or at elevated temperature.
4. Pack Appearance
PCR plastic may have:
- Slight colour variation due to thermal degradation, yellowish to dark colour.
- Less clarity compared to virgin plastic.
5. Mechanical Strength
Strength and durability may be slightly lower than virgin plastic.
Future of PCR Plastic in Pharma
The future looks promising for PCR plastic in pharmaceutical packaging.
1. Rapid Growth of Chemical Recycling
As technology improves, chemical recycling will be available for primary packaging.
2. Digital Material Tracking
Projects like Digital Product Passport (HolyGrail 2.0) are working on:
- Better waste sorting.
- Improved traceability.
- Higher recycling efficiency.
3. Stronger Regulations
In the future, regulatory bodies may introduce clear guidelines for PCR use in pharmaceuticals.
4. Industry Collaboration
Pharma companies, recyclers and regulators are working together to make PCR safer for food and pharmaceutical packaging.
Conclusion
PCR plastic in pharmaceutical packaging is not a complete replacement for virgin plastic yet, but it is definitely a step in the right direction.
Due to safety concerns, its use is currently limited—especially for primary packaging.
But with proper recycling processes, advanced testing and careful design, it can be used in many non-contact applications.
At the same time, environmental pressures, increasing plastic waste and sustainability goals are pushing the pharmaceutical industry to explore sustainable packaging.
With advancements in chemical recycling, better regulations and improved quality control, PCR plastic has the potential to play a bigger role in the future.
By using PCR plastic responsibly, the pharmaceutical industry can move towards a more sustainable and circular packaging system, without compromising safety.